Electric and Hybrid Vehicles [3 ed.] 9781032556802, 9781032556796, 9781003431732

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Electric and Hybrid Vehicles

Electric and hybrid vehicles are now the present, not the future. This straightforward and highly illustrated full-colour textbook is endorsed by the Institute of the Motor Industry (IMI) and introduces the subject for further education and undergraduate students as well as technicians and workshop owners, with sections for drivers who are interested to know more. This new edition contains extensively updated content, especially on batteries, charging and the high-voltage pathway and includes all new case studies and new images, photos and flow charts throughout. It covers the different types of electric vehicle, costs and emissions and the charging infrastructure before moving on to explain how hybrid and electric vehicles work. A chapter on electrical technology introduces learners to subjects such as batteries, control systems and charging, which are then covered in more detail within their own chapters. The book also covers the maintenance and repair procedures of these vehicles, including diagnostics, servicing, repair and first-responder information. The book is particularly suitable for students studying towards IMI Level 1 Award in Hybrid Electric Vehicle Awareness, IMI Level 2 Award in Hybrid Electric Vehicle Operation and Maintenance, IMI Level 3 Award in Hybrid Electric Vehicle Repair and Replacement, IMI Level 4 Award in the Diagnosis, Testing and Repair of Electric/Hybrid Vehicles and Components, IMI accreditation, City & Guilds (C&G) and all other EV/hybrid courses. Tom Denton is the leading UK automotive author with a teaching career spanning from lecturer to head of automotive engineering in a large college. His numerous bestselling textbooks have been endorsed by all leading professional organisations and are used by automotive students and technicians across the world. Hayley Pells is Policy Manager at the Institute of the Motor Industry (IMI), an experienced MOT tester, and owner of award-winning Avia Sports Cars Ltd. She is a versatile automotive aftermarket writer, regularly published since 2007, an authoritative public speaker and consultant specialising in digital literacy, blended learning and electric vehicle technology.

Electric and Hybrid Vehicles

Third Edition

Tom Denton and Hayley Pells

Cover image: Tom Denton and Hayley Pells First published 2024 by Routledge 4 Park Square, Milton Park, Abingdon, Oxon OX14 4RN and by Routledge 605 Third Avenue, New York, NY 10158 Routledge is an imprint of the Taylor & Francis Group, an informa business © 2024 Tom Denton and Hayley Pells The right of Tom Denton and Hayley Pells to be identified as authors of this work has been asserted in accordance with sections 77 and 78 of the Copyright, Designs and Patents Act 1988. All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form or by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying and recording, or in any information storage or retrieval system, without permission in writing from the publishers. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data Names: Denton, Tom, author. | Pells, Hayley, author. Title: Electric and hybrid vehicles / Tom Denton and Hayley Pells. Description: Third edition. | New York, NY : Routledge, 2024. | Includes index. Identifiers: LCCN 2023031345 | ISBN 9781032556802 (hardback) | ISBN 9781032556796 (paperback) | ISBN 9781003431732 (ebook) Subjects: LCSH: Electric vehicles. | Hybrid electric vehicles. Classification: LCC TL220 .D4443 2024 | DDC 629.22/93—dc23/ eng/20230731 LC record available at https://lccn.loc.gov/2023031345 ISBN: 978-1-032-55680-2 (hbk) ISBN: 978-1-032-55679-6 (pbk) ISBN: 978-1-003-43173-2 (ebk) DOI: 10.1201/9781003431732 Typeset in Univers by Apex CoVantage, LLC

Contents Preface About the authors Acknowledgements 1 Introduction to electric vehicles 1.1 Types of electric vehicle 1.1.1 Introduction 1.1.2 Pure electric vehicles 1.1.3 Hybrid electric vehicles 1.1.4 Plug-in hybrid electric vehicles 1.1.5 How to recognise an EV 1.2 Safety 1.2.1 High-voltage 1.2.2 Quiet operation 1.2.3 Engines 1.2.4 Personal protective equipment 1.2.5 Work on electric vehicles 1.2.6 Emergencies 1.2.7 EVs are perfectly safe! 1.3 Driving 1.3.1 Driving an EV 1.3.2 Range 1.3.3 Range anxiety 1.3.4 Other advantages 1.4 Charging 1.4.1 Location of charging ports 1.4.2 Charging methods 1.4.3 Time to recharge 1.5 Test cycle and emissions 1.5.1 Carbon dioxide 1.5.2 Worldwide harmonised light vehicles test procedure

x xi xiii 1 1 1 1 2 2 2 3 3 3 3 4 4 4 4 4 4 5 5 6 6 6 6 6 6 6

7

1.6

1.5.3 Life cycle assessment 1.5.4 Intelligent programming Fear, uncertainty and doubt 1.6.1 Introduction 1.6.2 EV myths 1.6.3 EV speed

2 Safe working, tools and hazard management 2.1 General safety precautions 2.1.1 Introduction 2.1.2 Safety 2.1.3 IMI TechSafe™ 2.1.4 General safety guidance 2.1.5 General risks and their reduction 2.2 High-voltage safety precautions 2.2.1 Introduction 2.2.2 Low and high-voltage 2.2.3 Defining high-voltage 2.2.4 Personal protective equipment (PPE) 2.2.5 High-energy cables and components 2.2.6 AC electric shock 2.2.7 DC electric shock 2.2.8 Protection devices 2.3 Safe work process 2.3.1 Risks of working with EVs 2.3.2 Work categories 2.3.3 Valeting, sales and other lower risk activities 2.3.4 Incident response, including emergency services and vehicle recovery

9 10 10 10 11 13

15 15 15 15 16 17 18 19 19 19 19 19 20 21 24 25 26 26 26 26

27

v

Contents 2.3.5

2.4

2.5

2.6

Maintenance and repair, excluding high-voltage electrical systems 2.3.6 Working on high-voltage electrical systems 2.3.7 Work processes 2.3.8 Lifting techniques 2.3.9 Annual inspections Hazard management 2.4.1 Initial assessment 2.4.2 Fire Tools and equipment 2.5.1 Introduction 2.5.2 Hand tools 2.5.3 Test equipment 2.5.4 Workshop equipment 2.5.5 High-voltage tools 2.5.6 Scanner Equality, diversity and inclusion (EDI) 2.6.1 Authors’ comment 2.6.2 Institute of the Motor Industry (IMI) 2.6.3 What is equality? 2.6.4 What is diversity? 2.6.5 What is inclusion? 2.6.6 What are the protected characteristics?

3.1.9

27

27 28 30 31 31 31 32 32 32 32 33 39 40 40 42 42 42 42 42 43 43

3 Electrical and electronic principles 45 3.1 Basic electrical principles 45 3.1.1 Introduction 45 3.1.2 Electron and conventional flow 46 3.1.3 Effects of current flow 47 3.1.4 Fundamental quantities 47 3.1.5 Describing electrical circuits 50 3.1.6 Conductors, insulators and semiconductors 50 3.1.7 Factors affecting the resistance of a conductor 50 3.1.8 Resistors and circuit networks 51

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3.2

3.3

Magnetism and electromagnetism 3.1.10 Electromagnetic induction 3.1.11 Mutual induction 3.1.12 Basic motor principle Definitions and laws 3.2.1 Ohm’s law 3.2.2 Lenz’s law 3.2.3 Kirchhoff’s laws 3.2.4 Faraday’s law 3.2.5 Fleming’s rules 3.2.6 Ampere’s law 3.2.7 Summary Electronic components 3.3.1 Introduction 3.3.2 Components 3.3.3 Integrated circuits

4 Electric vehicle technology 4.1 Electric vehicle layouts 4.1.1 Identifying electric vehicles 4.1.2 Single motor 4.1.3 Wheel motors 4.2 Hybrid electric vehicle layouts 4.2.1 Introduction 4.2.2 Classifications 4.2.3 Operation 4.2.4 Configurations 4.2.5 48 V hybrid system 4.2.6 Porsche 800 V performance battery system 4.2.7 Hybrid control systems 4.2.8 Hybrid case study 4.2.9 Efficiency 4.3 Cables and components 4.3.1 High-voltage cables 4.3.2 Components 4.3.3 Inverter developments 4.3.4 ECE-R100 4.4 Other systems 4.4.1 Heating and air conditioning 4.4.2 Thermal challenges 4.4.3 Liquid cooling

52 52 53 53 54 54 54 54 54 55 55 55 55 55 56 59 61 61 61 62 63 64 64 65 66 68 72

75 77 77 79 81 81 82 83 85 86 86 87 87

Contents 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8

4.5

4.6

Heat pumps Brakes Power-assisted steering DC-to-DC converter Thermal management case study 4.4.9 Radiant heating High-voltage safety system 4.5.1 Introduction 4.5.2 Pilot line 4.5.3 Crash safety 4.5.4 Insulation resistance Heavy vehicles 4.6.1 Overview 4.6.2 Heavy vehicle options 4.6.3 Bus and coaches

5 Batteries 5.1 Overview 5.1.1 Describing a battery 5.1.2 What is a kilowatt-hour? 5.1.3 Battery life and recycling 5.1.4 State of charge 5.1.5 State of health 5.2 Types of battery 5.2.1 Introduction 5.2.2 Lead-acid batteries (Pb–PbO2) 5.2.3 Alkaline (Ni-Cad, Ni-Fe and Ni–MH) 5.2.4 Sodium–nickel chloride (Na–NiCl2) 5.2.5 Sodium-sulphur (Na-S) 5.2.6 Lithium-ion (Li-ion) 5.2.7 Lithium-ion bladebattery case studies 5.2.8 Tesla battery case study 5.2.9 Fuel cells 5.2.10 Super-capacitors 5.2.11 Comparing energy storage methods 5.3 Battery technologies 5.3.1 Ambient temperature 5.3.2 Battery temperature 5.3.3 Thermal runaway 5.3.4 Solid-state batteries 5.3.5 Swarm intelligence

88 88 89 90 90 91 93 93 93 95 96 96 96 98 99 105 105 105 106 108 109 110 111 111 111 112 114 115 115 117 119 120 122 122 124 124 124 127 127 129

5.4

Research and development 5.4.1 Battery research 5.4.2 Toyota 1500 km battery 5.4.3 Fire detection 5.4.4 Leading edge (lithium-air) 5.4.5 Obituary

6 Motors and control systems 6.1 Introduction 6.1.1 Types of motor 6.1.2 Trends 6.2 Construction and function of electric motors 6.2.1 AC motors: basic principle 6.2.2 Asynchronous motor 6.2.3 Synchronous motor: permanent excitation 6.2.4 DC motor: series wound 6.2.5 DC motor: separately excited shunt wound 6.2.6 Electronically commutated motor 6.2.7 Switched reluctance motor 6.2.8 Motor efficiency 6.2.9 Motor torque and power characteristics 6.2.10 Winding shapes and insulation 6.2.11 Axial and radial windings 6.2.12 Drive motor developments and case studies 6.3 Control system 6.3.1 Introduction 6.3.2 Basic operation 6.3.3 Start up and shut down 6.3.4 High-voltage DC relays 6.3.5 Power control 6.3.6 Pulse-width modulation 6.3.7 Sensors 6.3.8 Battery 6.3.9 Battery management systems

130 130 133 133 135 135 137 137 137 137 137 137 137 138 138 139 139 141 143 144 144 145

146 148 148 148 150 152 152 154 154 156 157

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Contents 6.3.10 Cell balancing 6.3.11 Component cooling 7 Charging 7.1 Charging, standards and infrastructure 7.1.1 Infrastructure 7.1.2 Standardisation 7.1.3 Charging time and cost 7.1.4 Charging methods, modes and plugs 7.1.5 Communication 7.1.6 Fast charging 7.1.7 Vehicle-to-grid 7.1.8 Charging case study 7.2 Wireless power transfer 7.2.1 Introduction 7.2.2 Stationary WPT 7.2.3 Dynamic WPT 8 Maintenance, repairs and replacement 8.1 Before work commences 8.1.1 Introduction 8.1.2 Technical information 8.1.3 De-energising 8.2 During work 8.2.1 Maintenance intervals 8.2.2 Repairs affecting other vehicle systems 8.2.3 Inspect high-voltage components 8.2.4 Cables 8.2.5 Battery 8.2.6 Other components 8.3 Remove and replace 8.3.1 High-voltage components 8.3.2 Battery pack 8.3.3 Low-voltage components 8.4 Completion of work 8.4.1 Re-energising 8.4.2 Results, records and recommendations

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157 160

8.5

163 163 163 165 165 167 171 173 175 175 178 178 178 181

8.6

8.7 185 185 185 185 187 187 187 188 188 188 189 189 189 189 191 191 192 192 192

Recovery and roadside assistance 8.5.1 Introduction 8.5.2 Emergency start 8.5.3 Roadside repairs 8.5.4 Recovery 8.5.5 Towing 8.5.6 Emergency response 8.5.7 Fire 8.5.8 Damaged vehicle delivery 8.5.9 Accident and incident reporting Transportation and storage 8.6.1 Electric vehicles 8.6.2 High magnetic strength components (motors) 8.6.3 High-voltage batteries 8.6.4 Storage of cells and battery packs Recycling industry guidance

9 Diagnostics 9.1 Diagnostic operations 9.1.1 Introduction 9.1.2 Live data 9.1.3 Insulation testing 9.1.4 Equipotential bonding 9.2 Diagnostic tools and equipment 9.2.1 Introduction 9.2.2 De-energisation procedures 9.2.3 Two-pole tester 9.2.4 Multimeter and insulation tester 9.2.5 Amp clamp 9.2.6 Oscilloscope 9.2.7 Differential probe 9.2.8 Scanner 9.2.9 Summary 9.3 Non-invasive measurements 9.3.1 Introduction 9.3.2 Known good waveforms and measurements

193 193 193 193 194 194 194 195 196 197 197 197

197 197 198 199 201 201 201 201 203 206 212 212 212 214 214 215 215 216 216 217 217 217

217

Contents

9.4

9.5

9.6

9.7

9.3.3 COP and signal probe 9.3.4 Current flow: HVAC 9.3.5 Current flow: motor 9.3.6 Summary Charging testing 9.4.1 Protocol 9.4.2 Communication 9.4.3 Breakout box 9.4.4 Charging waveforms Three-phase testing 9.5.1 Operation 9.5.2 Motor drive waveforms Batteries 9.6.1 Battery repairs 9.6.2 Balancing Summary

10 High-voltage pathway for the independent workshop 10.1 Introduction 10.2 Analysing the EV/hybrid market 10.2.1 Demographics of EV/hybrid owners 10.2.2 Common issues that require garage services 10.2.3 Projected growth of the EV/hybrid market 10.3 Adapting your business model 10.3.1 Adjusting service prices 10.3.2 Offering EV-specific services 10.3.3 Building relationships with EV/hybrid owners

217 218 219 220 220 220 221 221 222 222 222 222 223 223 225 226

227 227 228 228 229 230 230 230 231 231

10.4 Setting up the workspace for EV/hybrid maintenance 10.4.1 High-voltage safety considerations 10.4.2 EV-specific equipment placement 10.4.3 Adequate ventilation for battery work 10.5 Building relationships with suppliers, industry associations and technology providers 10.5.1 Benefits of relationships 10.5.2 How to establish these relationships 10.6 Opportunities and challenges 10.6.1 The growing market for EV repair and maintenance 10.6.2 Potential challenges and how to overcome them 10.7 Suggested checklist for transitioning to EV/hybrid maintenance 10.8 Summary 10.9 Case studies 10.9.1 Lindleys autocentres (Nottingham) 10.9.2 Cleevely EV (Cheltenham) Index

232 232 233 233

234 234 235 236

236

236

237 240 241 241 241 243

ix

Preface This third edition of Electric and Hybrid Vehicles is aimed at students who are taking a course in automotive technology or are interested in learning for themselves about this fascinating industry. I am delighted to be partnering on this book with my friend and colleague Hayley Pells, a multiaward-winning owner of a highly respected service and repair business, Avia Autos, in Bridgend, South Wales, and the Institute of the Motor Industry’s policy and public affairs lead. Comments, suggestions and feedback are always welcome at my website: www.tomdenton.org. Several other books are available too: X Automobile Mechanical and Electrical Systems X Automobile Electrical and Electronic Systems X Automobile Advanced Fault Diagnosis X Alternative Fuel Vehicles X Automated Driving and Driver Assistance Systems X Automotive Technician Training We never stop learning, so I hope you find automotive technology as interesting as we still do.

x

About the authors Tom Denton has been researching and writing best-selling automotive textbooks for over 30 years. His published work is endorsed by all leading professional organisations and used by automotive students across the world. He has taught college students at all levels and always helped them achieve the best results. Tom was also a staff tutor and an associate lecturer for the Open University. His postgraduate education in all aspects of technology and education, as well as many years of practical experience, has given him a broad base from which to approach and teach this interesting yet challenging subject. As a fellow of the Institute of the Motor Industry and a member of the Institute of Road Transport Engineers and the Society of Automotive Engineers, he keeps in contact with the latest technologies and innovations across all aspects of this fascinating industry. As well as publishing 45 textbooks, Tom has created amazing support materials and eLearning courses. Hayley Pells expresses her gratitude for the opportunity to collaborate with Tom Denton, an esteemed technical author and experienced automotive engineer, who serves as a friend and inspiration. Throughout her time in the motor industry, which started operating an independent workshop, she discovered that the versatility of skills learned can be applied to both work and personal life. As a professional writer, she is published in many industry journals offering insight and information about the sector. She is respected for her efforts championing accessible education working with the upskilling of existing professionals, post-16 apprenticeships and numerous pre-16 careers and enterprise projects which showcase motor industry careers. She is a fellow of the Institute of the Motor Industry, holding their Patron’s Award recognising her work campaigning for gender equality.

xi

About the authors

www.tomdenton.org There are extensive updates in this third edition. Thank you to friends and colleagues who sent feedback or made suggestions. On our website, you will also find lots of free online resources to help with your studies. These resources work with the book and are ideal for self-study or for teachers helping others to learn. The resources include over 20 videos to support your EV learning journey.

xii

Acknowledgements Over the years, many people have helped in the production of my books. I am, therefore, very grateful to the following companies who provided information and/or permission to reproduce photographs and/or diagrams: AA AC Delco ACEA Alpine Audio Systems Audi Autologic Data Systems BMW UK Bosch Brembo Brakes C&K Components Citroën UK Clarion Car Audio Continental CU-ICAR Dana Delphi Media Denso Department for Transport Draper Tools Eberspaecher First Sensor AG Fluke Instruments UK Flybrid Systems Ford Motor Company FreeScale Electronics Garage Hive General Motors GenRad Google (Waymo) haloIPT (Qualcomm)

Hella HEVRA HEVT Honda Hyundai Institute of the Motor Industry (IMI) Jaguar Cars Kavlico Ledder Loctite Lucas UK LucasVarity Mahle Maserati MATLAB/Simulink Mazda McLaren Electronic Systems Mennekes Mercedes MIT Mitsubishi Most Corporation NASA NGK Plugs Nissan Nvidia Oak Ridge National Labs Peugeot Philips

Pico Technology Automotive Pierburg Pioneer Radio Pixabay Porsche Protean Electric Renesas Ricardo Rimac Rolec Rover Cars Saab Media SAE Scandmec Schaeffler Shutterstock SMSC Snap-on Tools Society of Motor Manufacturers and Traders (SMMT) Sofanou Solvay Sun Electric Tesla Motors Texas Instruments Thatcham Research Thrust SSC Land Speed Team Topdon UK Toyota

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Acknowledgements Tracker Tula Unipart Group Valeo Varta

Vauxhall VDO Instruments Volkswagen Volvo Cars Volvo Trucks

Wikimedia YASA ZF

If we have used any information or mentioned a company name that is not listed here, please accept our apologies and let us know so it can be rectified as soon as possible.

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CHAPTER

1

Introduction to electric vehicles 1.1  Types of electric vehicle 1.1.1  Introduction Here is an interesting thought to start with: The history of electric vehicles began between 1832 and 1839 when Robert Anderson of Scotland built a prototype electric carriage. Gustave Trouvé’s tricycle (1881) is acknowledged as the world’s first electric car. Earlier than many would have expected, I’m sure! Figure 1.2  Volkswagen ID7–700 km WLTP range (Source: Volkswagen Media)

1.1.2  Pure electric vehicles Pure electric vehicles (PEVs) have a battery instead of a fuel tank and an electric motor instead of an internal combustion engine (ICE). They are also described as battery electric vehicles (BEVs) or just electric vehicles (EVs). EVs are powered only by electricity and are plugged in to be recharged. They do not produce any tailpipe emissions. Most now have a real-world range of 100–300 miles on a single charge. Figure 1.1  Gustave Trouvé’s tricycle – limited range (1881) DOI: 10.1201/9781003431732-1

1  Introduction to electric vehicles Examples include the Nissan LEAF, Volkswagen ID3/4, Jaguar iPace, Audi Q4 e-tron and Tesla Model 3.

1.1.4  Plug-in hybrid electric vehicles Plug-in hybrid electric vehicles (PHEVs) have a battery, electric drive motor and an internal combustion engine (ICE). They can be driven using the ICE, the electric drive motor or a combination of the two. They can be recharged from an external power source. Typical PHEVs have a pure-electric range of 20 to 50 miles. Once the battery is discharged, journeys can continue in hybrid mode, meaning that there is no range limit. PHEV examples include the Mitsubishi Outlander PHEV, BMW 330e and Volkswagen Golf GTE.

Figure 1.3  Audi Q4 e-tron PEV (Source: Audi AG)

1.1.3  Hybrid electric vehicles Hybrid electric vehicles (HEVs) are powered by an internal combustion engine in combination with one or more electric motors that use energy stored in batteries. HEVs combine the benefits of good fuel economy and low tailpipe emissions with the power and range of conventional vehicles. The standard type of HEV cannot be plugged in and charged from an external source.

Range-extended electric vehicles (E-REVs) are a type of PHEV, but they have an internal combustion engine and generator on board to recharge the battery when it is discharged. An example was the early BMW i3 but these are not now available as new.

Examples include the Toyota Prius, Honda CRV and BMW 3 Series.

Figure 1.5  Volkswagen Golf GTE

1.1.5  How to recognise an EV

Figure 1.4  Honda CRV HEV (Source: Honda Media)

2

Externally, the easiest way to recognise an EV (or HEV or PHEV!) is knowing the make or model of the vehicle or. if not, then by the badging. Many include an ‘E’ in the name, e-tron, GTE or BMW 330e, for example. The other outside feature will be the charging port. This may be under what looks like a

1  Introduction to electric vehicles fuel filler flap or, in some cases, behind the manufacturer’s badge.

X air conditioning X heater

Inside the car, the dashboard will be a little different and, for example, will show the word ‘Ready’ when switched on – this is the equivalent of having the engine running. There is also likely to be a battery meter showing the state of charge.

All of these components if accident damaged or dismantled are capable of giving a fatal electric shock. Again, all are perfectly safe for normal use, so don’t worry.

Under the bonnet, the most obvious feature will be bright orange cables. These are the ones that carry the very high-voltage. They are perfectly safe to touch, if they are not damaged, but best left to the experts. Many pure EVs have a green stripe on the number plates. If all else fails when identifying a vehicle, we could look in the driver’s handbook!

Figure 1.7  Danger sign

1.2.2  Quiet operation

Figure 1.6  Audi Q4 Sportback 50 e-tron quattro (Source: Audi Media)

1.2 Safety 1.2.1  High-voltage Clearly a key safety issue with electric vehicles, of any type, is high-voltage. This is usually 400 volts or more (the Porsche Taycan, for example, is 800 volts), domestic mains voltage is 230 volts and that is dangerous! The high-voltage components include the X battery X power controller X motor

One aspect of a moving EV is that it can be very quiet. It is important, therefore, to look and listen when cars could be moving in the workshops or showrooms as well as car parks or anywhere similar. Many EVs now have a noise generator that plays sound through an external speaker to improve safety. Although, smaller EVs, like heavy quadricycles, do not, so it always pays to be careful when working around such quiet vehicles.

1.2.3  Engines On some hybrid vehicles, the engine can start without warning. This happens when the clever electronic systems detect that the battery is becoming discharged – the engine starts to recharge it. This will not happen if the vehicle is switched off and the keys removed.

3

1  Introduction to electric vehicles 1.2.4 Personal protective equipment When working on certain aspects of a high-voltage vehicle, technicians will use appropriate personal protective equipment (PPE). However, no PPE is required by owners and users of EVs.

1.2.5 Work on electric vehicles When work is being carried out, it is important that you do not approach an electric vehicle if it is cordoned off or displaying HV warning signs unless specifically asked to by a qualified person. Equally, you should never attempt to move a damaged electric vehicle without permission. A technician should not work on the highvoltage or highly magnetic components of an EV if they have a heart pacemaker or other medical device such as an insulin pump fitted. Normal service and repair operations are fine. If in doubt, check the manufacturer’s guidance. Unless you are an EV-qualified technician carrying out diagnostic work, you should unplug vehicle from the charge socket before commencing any operation. An example would be when washing or valeting the vehicle. If you see or hear anything unusual when operating or working on an EV, such as smoke or popping/hissing noises from battery or elsewhere, you should report this immediately.

1.2.6 Emergencies As with all vehicle types, dangerous situations can arise. In the event of a fire, the normal workplace procedures must be followed. If a person suffers an electric shock, then the instructions and processes outlined on the ‘Electric Shock’ posters should be followed. A high-voltage vehicle that has been flooded or even completely submerged is not a particular danger but should only be moved or worked on by a qualified person.

1.2.7 EVs are perfectly safe! It is important to stress again here that for normal use, drivers and passengers are perfectly safe in an EV. As well as insulation and shields, there are very sophisticated safety features built in; for example, the high-voltage is shut down in an impact. Clearly, you should not interfere with any complex systems on a vehicle and the high-voltage, in particular, unless you are a trained technician.

1.3 Driving 1.3.1 Driving an EV Driving an EV is similar for almost every model. Turn the key or, more likely, press the Power button on the dash to turn the car on (Ready mode). Select Drive, which will usually be with a traditional gear lever, like the one in an automatic car. Some manufacturers have moved the drive selector to the dashboard. Twist the selector towards the windscreen to go forwards and towards you for reverse. Other EVs may have a rotary dial with gear markings around it. With these, just turn the dial to select forward or reverse. Pure EVs do not have gears or a clutch pedal, so press the accelerator pedal to go and the brake pedal to stop. It is not possible to stall an EV.

Figure 1.8  Always disconnect the charger before washing or working on a vehicle

4

EVs are very smooth and quiet and a pleasure to drive. The instant torque of the electric

1  Introduction to electric vehicles motors means good acceleration, and, in some cars, amazing acceleration, so take care not to go too fast! Cruising at about 60 mph with smooth, gentle acceleration and gentle braking is the most economical. EVs use something called regenerative braking. This converts movement energy into electricity to recharge the batteries. Because of this, an EV may slow down more than you expect when you lift the accelerator pedal. However, you can use this to your advantage as it makes the drive smoother and produces less wear on the brakes.

winter. It also depends very much on driving style (as it does for an ICE vehicle).

1.3.3  Range anxiety Range anxiety is the fear that an electric vehicle will not have enough battery charge to reach its destination, leaving the motorist stranded. This anxiety is particularly prominent when considering long-distance travel, driving on roads where charging points could be few and far between or if someone is new to the technology. However, the charging infrastructure is improving every day. The other key improvement is the actual range a vehicle will now achieve. These examples are based on standard test conditions, called the worldwide harmonised light vehicles test procedure (WLTP), but even if you reduce them by 25% to make them more ‘real world’, they are still good: X Tesla Model 3 Long Range: 379 miles range X Kia e-Niro Long Range: 283 miles range X DS 3 Crossback: 199 miles range X MINI Cooper S 1: 144 miles range Just like with an ICE vehicle, it is important to choose a car that matches the user’s needs. Interestingly, the average daily return journey length in the UK and EU is about 20 miles.

Figure 1.9  One pedal to go and one to stop! (Source: Tesla)

1.3.2  Range The range of an EV is how far it can travel on a full charge. In other words, starting with the battery at 100% and driving it until the battery is completely discharged. Vehicle range depends on a number of factors, including battery size, vehicle size, aerodynamics, battery heating efficiency and outside temperature. It is entirely normal for an electric vehicle to travel more miles on a charge on a hot summer day than a cold day in

Figure 1.10  Kia e-Niro (Source: Kia Media)

5

1  Introduction to electric vehicles 1.3.4  Other advantages While the initial upfront purchase price of an electric or plug-in hybrid vehicle can be higher, this can be offset by reduced running costs: X A full charge in a pure electric vehicle will typically cost about half of the equivalent in fuel when owners charge at home and have access to an off-peak electricity tariff. X There are fewer mechanical components in an electric vehicle compared with conventional vehicles, which often results in lower servicing and maintenance costs. X There is a lower vehicle excise duty (VED). X EVs offer free or cheaper access to low emission and congestion zones. X There is free parking for electric vehicles available in some towns and cities. X There are currently incentives for company cars to switch to greener travel.

1.4 Charging 1.4.1 Location of charging ports The charging port is where you plug in the cable that connects to the mains or to a dedicated charger. It may be under what looks like a fuel filler flap or, in some cases, behind the manufacturer’s badge. There are a few different types, and they can be at the front, rear or on the side of the vehicle.

Key Fact DC chargers can deliver power faster as they have large inverters in the charging station, and this bypasses the vehicle’s on-board inverter, delivering power straight to the battery.

1.4.3  Time to recharge A typical recharge, particularly when travelling, is from 20% to 80%. Table 1.1 shows average times of the different methods for a 100 kWh battery (which is a big battery): However, even though very fast charging is possible, Figure 1.11 offers some very important advice for prolonging the life of a battery.

1.5 Test cycle and emissions

1.4.2 Charging methods

1.5.1 Carbon dioxide

There are essentially three ways to charge an EV:

Electric vehicles have zero emissions at the point of use, so-called ‘tank-to-wheel’, when powered only by the battery. The ‘well-to-wheel’ analysis includes the CO2 emissions during electricity generation, which depend on the current mixture of fuels used to make the electricity for the grid. To make a correct comparison with emissions from all cars, it is necessary to use the ‘well-towheel’ figure, which includes the CO2 emissions during production, refining and distribution of petrol/diesel.

1. Trickle charge: This is the slowest method of charging your EV at home, using a standard 230 V plug. It is only recommended in emergencies. 2. AC charge: Having a wall box installed lets you charge 3–4 times faster using AC domestic charging. AC public charging is also widely available and is popular for workplaces too.

6

3. DC charge: This is the fastest way to charge an EV, but older EVs and PHEVs do not have this option. These public DC fastcharging stations usually have power rated at 50 kW and above. With this method, for example, you can top up a 60 kWh battery from 20% to 80% in about 40 minutes. There are now also some ultra-fast charging stations that provide 150 kW and 350 kWh chargers will become available in the future.

1  Introduction to electric vehicles Table 1.1  Typical charging times Device

Power (kW)

Approximate time (0% to 100%)

Approximate time (20% to 80%)

Domestic EV charger

3

33 hours

20 hours

Domestic wall box charger

7

14 hours

9 hours

AC fast charger

22

4 hours 30 mins

3 hours

DC fast charger

60

1 hour 40 mins

1 hour

DC ultra-fast charger

150

40 mins

24 mins

DC fastest charger*

350

16 mins

10 mins

*becoming available at the time of writing but not in common use and not suitable for many cars

Figure 1.11  Prolonging the life of a battery (in your phone and car)

Key Fact Electric vehicles have zero emissions at the point of use, so-called ‘tank-to-wheel’. Electricity production continues to decarbonise because of reduced reliance on oil and coal, so the overall emission figure for running an EV will drop further. Tailpipe emissions also include oxides of nitrogen (NOx) and particulate matter (tiny particles of solid or liquid matter suspended in a gas or liquid) that contribute to air pollution. This is why any vehicle operating only on battery power will play a significant role in improving local air quality.

1.5.2  Worldwide harmonised light vehicles test procedure The worldwide harmonised light vehicles test procedure (WLTP) is a global standard for determining levels of pollutants and CO2

emissions, fuel or energy consumption and electric range (Figure 1.12). It is used for passenger cars and light commercial vans. Experts from the EU, Japan and India, under guidelines of the UNECE World Forum for Harmonization of Vehicle Regulations, developed the standard. It was released in 2015. Definition WLTP: Worldwide harmonised light vehicles test procedure. Like all previous test cycles, the WLTP has its drawbacks, but it is a good attempt to make the test more realistic. The key thing is that a standardised test allows vehicles to be compared accurately, even if the figures differ from real-world driving. It includes strict guidance regarding conditions of dynamometer tests and road load (motion resistance), gear changing, total car weight (by including

7

1  Introduction to electric vehicles

Figure 1.12  WLTP test cycles optional equipment, cargo and passengers), fuel quality, ambient temperature and tyres and their pressure. Three different cycles are used depending on vehicle class defined by power/ weight ratio PWr in kW/tonne (rated engine power/kerb weight): X Class 1 – low power vehicles with PWr ≤ 22 X Class 2 – vehicles with 22 < PWr ≤ 34 X Class 3 – high-power vehicles with PWr > 34 Most modern cars, light vans and busses have a power/weight ratio of 40–100 kW/t, so they belong to Class 3, but some can be in Class

8

2. In each class, there are several driving tests designed to represent real-world vehicle operation on urban roads, extra-urban roads, motorways and freeways. Key Fact Most modern cars, light vans and busses have a power/weight ratio of 40–100 kW/t, so belong to WLTP Class 3. The WLTC driving cycle for a Class 3 vehicle is divided into four parts:

1  Introduction to electric vehicles 1. Low 2. Medium 3. High 4. Extra-high speed If Vmax < 135 km/h, the Extra-high speed part is replaced with a Low speed part.

1.5.3  Life cycle assessment To determine the carbon footprint of a vehicle, its life is divided into three phases (Figure 1.13): 1. Production 2. Use 3. Recycling For most manufacturers (Volkswagen is the example used here), the carbon footprint of the electrically propelled variants is already better than that of the corresponding vehicles with internal combustion engines. The same vehicle model but with different powertrains is used for this comparison. Key Fact To determine the carbon footprint of a vehicle, its life is divided into three phases:

X Production X Use X Recycling Electric vehicles offer a higher CO2 saving potential in all phases of the product cycle. Furthermore, it is of crucial importance for CO2 emissions whether the propulsion energy is generated from fossil or regenerative sources. As an example from 2019, the Golf TDI (Diesel) emits 140 g CO2/km on average over its entire life cycle, while the e-Golf reaches 119 g CO2/ km. A vehicle with an internal combustion engine creates most of its emissions during the use phase, that is, in the supply chain of the fossil fuel and the combustion. During this phase, the diesel reaches 111 g CO2/km. A corresponding vehicle with electric drive emits only 62 g CO2/km during this phase, the result of energy generation and supply. By contrast, most emissions from the batterypowered electric vehicle are generated in the production phase. According to life cycle assessment (LCA), a diesel vehicle generates 29 g CO2/km, while a comparable e-vehicle generates 57 g CO2/km.

Figure 1.13  Life cycle assessment

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1  Introduction to electric vehicles Battery production and the complex extraction of raw materials are responsible for the additional CO2 for e-vehicles. These emissions account for almost half of the CO2 emissions of the entire life cycle. During the use phase, CO2 emissions depend on the sources of energy production. They decrease as more regenerative energies are available. Life cycle assessment (LCA) is an intricate, complex and internationally standardised procedure to research the ecological balance sheet of vehicles. Among other things, carbon dioxide emissions are investigated during all production stages of the automobile: X The emissions generated by the extraction of raw materials, the production of components and the assembly of the car are included in the production phase. X The use phase includes both the emissions of the fuel and electricity supply and especially those of vehicle operation over 200,000 km. X Recycling evaluates dismantling and the potential savings of recycling.

The most efficient way to decelerate is by coasting because there is no active reduction in speed and no waste of energy. However, unless the battery SOC is less than 90%, there will be little or no energy recovery from regeneration. Driving in a large town or city makes coasting difficult. An energy-efficient urban acceleration-and-braking approach is therefore used. If conditions don’t permit the precalculated drive, the vehicle is operated by slow, light acceleration and gentle braking until opportunities for the preset strategies reappear. Key Fact The most efficient way to decelerate is by coasting.

Findings from the LCA mean that Volkswagen and other manufacturers can derive additional emission-reducing measures for life cycle engineering (LCE) and, specifically, optimise the CO2 balance.1

Savings of battery power of over 10% are potentially achievable and, in some cases, up to 50%, when compared to sportier driving styles.

1.5.4  Intelligent programming

1.6.1  Introduction

The intelligent programming of autonomous electric vehicles can result in energy savings. Most BEVs allow the driver a choice of driving styles, for example, economy, normal and sport. It is several years away yet, but an autonomous Level 4 to 5 vehicle can result in better miles per kW/h than a human driver. Map data is used to determine the route and details from the route such as speed limits, required turns, intersections and time factors are preprogrammed.

FUD is an acronym for fear, uncertainty and doubt, and there is a lot of it about in relation to electric and hybrid vehicles. This is perfectly understandable and often happens when things seem to be changing quickly. However, it can also be used as a tool for misinformation – and this is definitely the case with electric vehicles.

Driving dynamics, drag of the vehicle and changes in the battery state of charge (SOC) are also considered. SOC affects everything

10

from route selection to availability and usability of regenerative braking. Other factors that change during the route include vehicle-toinfrastructure transmissions (traffic control devices, for example), sensor data and camera readings from on-board devices and even changes in the weather.

1.6  Fear, uncertainty and doubt

Our personal view, and that of almost all motor manufacturers, is that EVs are part of the future, not only for their role in reducing emissions and global warming but because they are much nicer to drive than ICE vehicles for personal use.

1  Introduction to electric vehicles An electric car uses energy more efficiently. A fossil burner wastes 70–75% of the energy it burns, and fossil fuel is extracted, transported and refined before use, releasing vast amounts of CO2 never included in ‘tailpipe’ emissions. Even hydrogen fuel cell cars are much less efficient than a pure EV. This is because of the energy costs in creating, transporting and converting the hydrogen back to electricity. Hydrogen as a fuel has its advantages, particularly in plant and heavy-duty vehicles. Using the correct fuel source for the correct application is an environmentally responsible decision that many will have to make in order to reduce emissions that are harmful.

Figure 1.14  At the bottom of this mountain road in the French Alps, my EV had five more miles of range than it did at the top

1.6.2  EV myths Electric vehicles have a poor range because they run out of electricity after a short distance The average length of a commuter trip by car/ van across England and Wales is about 16 kilometres (10 miles). On average, European workers spend 1 hour and 24 minutes a day commuting, travelling 28.56 km (17.7 miles) in total. In terms of distance undertaken, about one-fifth of Europeans (23.3%) travel, on average, further than 40 km or even more each day, while 36.2% travel fewer than 10 km. Americans drive an average of 40 miles a day. Even the shortest-range electric vehicles claim to cover more than twice these distances before being recharged. However, a value of two-thirds of the claimed miles is a more realistic distance in the real world. Even if you halve the following WLTP figures (for example, for a really cold day or poor driving style), then for most commuting journeys, the vehicles are fine: X Tesla Model 3 Long Range: 379 miles/610 km range X Kia e-Niro Long Range: 283 miles/455 km range X DS 3 Crossback: 199 miles/320 km range X MINI Cooper S 1: 144 miles/232 km range X Volkswagen ID7: 435 miles/700 km range

Electric vehicles are slow The electric motor produces 100% of its torque instantly. This is the same at all speeds – in other words, a flat torque curve. One version of the Tesla Model S, when in Ludicrous mode, is one of the quickest production cars in the world – it has a 0–60 mph time of about 2.5 seconds.

Electric vehicles are expensive Figure 1.15  Electric London taxi – the driver of one of these said he saves £5,000 per year on fuel costs compared to the older diesel version

It is often claimed that EVs are more expensive than ICE vehicles – or are they? The cost of the battery is a defining factor here, but this is falling and is expected to drop further in the

11

1  Introduction to electric vehicles next few years. It is important to consider the longer-term cost. Over a period of time, even though some EVs are more expensive, the running costs are significantly less, so they can work out cheaper overall.

Electric vehicles are not safe In crash tests, EVs must meet the same, if not more, stringent standards as ICE vehicles – and they do! The high-voltage employed by EVs is definitely dangerous if worked on by untrained technicians, but this is now covered by schemes such as IMI TechSafe (see page 16). The high-voltages pose no risk to drivers and passengers, even in a crash. A recent study on vehicle fires concluded that the frequency and severity of fires and explosions from lithium-ion battery systems are comparable to, or less than, ICE cars.

Electric vehicles produce more emissions than ICE vehicles EVs convert at least 75% of the chemical energy in the batteries to mechanical energy at the wheels. ICE vehicles only convert about 25% of the energy stored in petrol/ gasoline. EVs do not produce tailpipe emission/ pollutants. They do produce emissions at the electricity generation plants, but the conversion here is still more efficient than an ICE. However, there is a significant trend towards greener power generation, so EVs are becoming cleaner every day. It is also important to consider the full life cycle of a vehicle – see Section 1.5.3 for more details.

Figure 1.16  Toyota Prius plug-in hybrid (Source: Toyota Media)

12

Electric cars are more expensive to service and repair EVs do need to be checked and serviced regularly like all complex machinery. However, there are far fewer moving parts to eventually fail. Comparing like-for-like vehicles at main dealers, servicing costs are less for EVs.

There are not enough public charging points Most EV charging is done at home or at work. However, in the UK (as of December 2019) the total number of locations which have a public charging point installed was 10,343, the number of devices at those locations was 16,495 and the total number of connectors within these devices was 28,541. The USA had over 20,000 electric car charging stations with more than 68,800 connectors. In 2021, the EU had an estimated 375,000 charging stations. In just over two years (April 2023), these numbers increased to: X 40,150 charging points located throughout the UK2 X 130,000 charging stations in the USA3 X 500,000+ charging points located across the EU4

Batteries only last a few years Most vehicle manufacturers warranty their battery packs for at least 8 years or 100,000 miles. Several reports have shown that Nissan

Figure 1.17  Toyota Prius presenting for Ministry of Transport (MOT) test

1  Introduction to electric vehicles LEAF models still had 75% of their battery capacity after 120,000 miles. One Tesla owner claims to have 90% of their car’s battery capacity, even after 200,000 miles.

the streets. With 1,914 hp produced by four electric motors, the electric hypercar reaches 0–60 mph in just 1.85 seconds and to 100 mph in 4.3 seconds.

We personally know of several 1997/8 Toyota Prius cars still running well on their original batteries. Up to 99% of EV batteries can be repaired, remanufactured, reused or recycled.

After an extensive five-year journey of development and rigorous testing, involving three generations of powertrain technology, 18 prototypes, 45 physical crash tests and over 1.6 million collective hours of research and development, the Rimac Nevera has reached a significant milestone as the first full production version rolls off Rimac’s newly established production line (2022/3). The hand-building process of the Nevera will now continue at a steady pace, with up to 50 units being crafted annually.

The power grid will not be able to handle the extra load Power grids across the UK, EU and USA can handle the expected growth in EVs for the foreseeable future without any significant change. This is because most EVs tend to be charged at night during off-peak hours and when demand is usually lowest. To balance the grid, it will be necessary to agree to methods of timing, such as competitive pricing for charging EVs during certain hours, but capacity is not the problem.

Reserves of rare earth metals used in batteries and motors will run out We first need to define the difference here between a resource and reserves of that resource. A resource is how much of a geologic commodity exists. It includes discovered and undiscovered amounts; therefore, it is a calculated estimate. Reserves are the amount of a resource that have been discovered. For this reason, they have a known quantity and are financially viable for extraction. This viability changes depending on technologies and demand. In other words, as demand for certain rare earth metals increases so do the available reserves. Other technological developments are also taking place. For example, motors now contain significantly less rare-earth element.

As we speak, the initial batch of cars, eagerly awaited by customers, is already in the process of assembly. Each Nevera undergoes a meticulous five-week final assembly line procedure, with various components and systems manufactured months in advance at Rimac facilities. Soon, these remarkable vehicles will be delivered to destinations worldwide through Rimac’s extensive network of 25 official dealer partners, spanning the United States, Europe, the Middle East and Asia. The Rimac Nevera stands as a testament to innovation, being the world’s first all-electric hypercar developed entirely from scratch.

1.6.3  EV speed The very first production version of the Rimac Nevera (Figure 1.18), the world’s fastest accelerating production car, is ready to take to

Figure 1.18  The Rimac Nevera is the world’s fastest accelerating production car (Source: Rimac)

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1  Introduction to electric vehicles major components, including an entirely new generation battery system, inverter, gearbox, motor, control systems, infotainment and more. Over a span of two years, the powertrain underwent three complete redesigns, showcasing the dedication and commitment of the team behind this groundbreaking achievement.

Notes Figure 1.19  Not quite as fast as the Rimac Nevera but this Citroen could be the future of local transport With a relentless pursuit of high-performance targets, Rimac has meticulously crafted and engineered most of the key systems in-house. Custom development was the norm for all

14

1 Source: Volkswagen Media. 2 https://www.gov.uk/government/statistics/ electric-vehicle-charging-device-statisticsoctober-2022/electric-vehicle-charging-devicestatistics-october-2022 3 https://usafacts.org/articles/how-many-electricvehicle-charging-stations-are-there-in-the-us/ 4 https://www.statista.com/statistics/955443/ number-of-electric-vehicle-charging-stations-ineurope/

CHAPTER

2

Safe working, tools and hazard management 2.1  General safety precautions 2.1.1  Introduction Safe working practices in relation to all automotive systems are essential, for your safety as well as that of others. When working on high-voltage systems, it is even more important to know what you are doing. However, you only have to follow two rules to be safe: X Use your common sense – don’t fool about. X If in doubt, seek help. The following section lists some particular risks when working with electricity or electrical systems, together with suggestions for reducing them. This is known as risk assessment.

very short time. The Honda Insight system, for example, uses a 144 V battery module to store regenerated energy. The Toyota Prius originally used a 273.6 V battery pack, but this was changed in 2004 to a 201.6 V pack. Voltages of 400 V are now common and some up to 700 V, so clearly, there are electrical safety issues when working with these vehicles. EV batteries and motors have high electrical and magnetic potential that can severely injure or kill if not handled correctly. It is essential that you take note of all the warnings and recommended safety measures outlined by manufacturers and in this resource. Any person with a heart pacemaker or any other electronic medical device should not work on an EV motor since the magnetic effects could be dangerous. In addition,

Definition Risk assessment: a systematic process of evaluating the potential risks that may be involved in an activity or undertaking.

2.1.2  Safety Electric vehicles (pure or hybrid) use high-voltage batteries so that energy can be delivered to a drive motor or returned to a battery pack in a

Figure 2.1  Volvo hybrid car (Source: Volvo Media) DOI: 10.1201/9781003431732-2

2  Safe working, tools and hazard management other medical devices such as intravenous insulin injectors or meters can be affected. Safety First EV batteries and motors have high electrical and magnetic potential that can severely injure or kill if not handled correctly. Most of the high-voltage components are combined in a power unit. This is often located behind the rear seats or under the luggage compartment floor (or the whole floor in a Tesla). The unit is a metal box that is completely closed with bolts. A battery module switch, if used, may be located under a small secure cover on the power unit. The electric motor is located between the engine and the transmission or as part of the transmission on a hybrid, or on a pure EV, it is the main driving component. A few vehicles use wheel motors too. The electrical energy is conducted to or from the motor by thick orange wires. If these wires have to be disconnected, switch off or de-energise the high-voltage system. This will prevent the risk of electric shock or short circuit of the high-voltage system. Safety First High-voltage wires are always orange. NOTE: Always follow the manufacturer’s instructions – it is not possible to outline all variations here.

2.1.3  IMI TechSafe™ IMI TechSafe™ is professional recognition within the IMI Professional Register. It identifies a member’s professionalism and safe working practice in the field of electric vehicles (EV) and other safety-critical vehicle systems such as autonomous or advanced driver assistance systems (ADAS). As well as proof of competence through the achievement of nationally recognised qualifications or IMI accreditations, having IMI TechSafe recognition means that the member keeps up-to-date through mandatory requirements for continuous professional development (CPD). These CPD requirements are decided and agreed upon by an IMI industry sector advisory group and are reviewed on a regular basis. Employers have a responsibility and duty of care to ensure their staff are competent to work on electric vehicles (EV) and that they meet the requirements of the Electricity at Work Regulations 1989. The repair of damaged electric vehicles and those with ADAS is covered within the British Standard, BS10125. Most insurance companies (work providers) support this by only giving work to businesses that meet the standard. Vehicle manufacturers set out repair methods and processes from a servicing and maintenance point of view as well as for the repair of damaged vehicles. These must be followed to ensure their own safety, the safety/ roadworthiness of the vehicle and the safety of the driver and other road users or pedestrians. IMI TechSafe recognition gives an employee the ability to easily demonstrate to colleagues, customers and professionals that they’re fully qualified to be working on EV vehicles and/or vehicles with ADAS

Figure 2.2  EV battery and drive components (Source: Porsche Media)

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Figure 2.3  Why do I need to be IMI TechSafe?

2  Safe working, tools and hazard management technologies. It is also seen as a badge of honour for those in the sector who hold it and can lead to increased employability as employers are searching for EV technicians to join their work forces. There are a few steps to take to gain IMI TechSafe recognition within the IMI Professional Register: X gain a qualifying achievement, for example, an IMI nationally recognised qualification or IMI accreditation X join the IMI membership community X take your place on the IMI’s Professional Register X gain IMI TechSafe recognition A vital part of the Professional Register and IMI TechSafe is ensuring those on it remain up-to-date with their knowledge, skills and competency. This is why CPD is a requirement to remain in IMI TechSafe recognition.

2.1.4  General safety guidance Before maintenance X Turn off the ignition switch and remove the key. X Switch off the battery module switch or de-energise the system. X Wait for five minutes before performing any maintenance procedures on the system. This allows any storage capacitors to be discharged. During maintenance X Always wear insulating gloves. X Always use insulated tools when performing service procedures to the highvoltage system. This precaution will prevent accidental short circuits. Interruptions When maintenance procedures have to be interrupted while some high-voltage components are uncovered or disassembled, make sure that X the ignition is turned off and the key is removed

Figure 2.4  High-voltage gloves (Class 0, short style)

X the battery module switch is switched off X no untrained persons have access to that area and prevent any unintended touching of the components. After maintenance Before switching on or re-energising the battery module after repairs have been completed, make sure that X all terminals have been tightened to the specified torque X no high-voltage wires or terminals have been damaged or shorted to the body X the insulation resistance between each high-voltage terminal of the part you disassembled and the vehicle’s body has been checked Working on electric and hybrid vehicles is not dangerous if the previous guidelines and the manufacturer’s procedures are followed. Before starting work, check the latest information – DON’T take chances. Dying from an electric shock is not funny. Crash safety: Electric vehicles are tested to the same high standards as other vehicles currently on UK roads. In February 2011, the first pure electric car was assessed and passed the renowned Euro New Car Assessment Programs (NCAP) test.

17

2  Safe working, tools and hazard management Pedestrian safety: The quietness of EVs is a benefit but can pose a threat to sight- and hearing-impaired people, particularly at low speeds. Having seen a vehicle, pedestrians are capable of reacting to avoid an accident at vehicle speeds up to 15 mph. However, research found that tyre noise will alert pedestrians to a vehicle’s presence at speeds greater than 12.4 mph.

2.1.5  General risks and their reduction Figure 2.5  High-voltage cables are always orange (Source: Volkswagen Media)

Table 2.1 lists some identified risks involved with working on ALL vehicles. The table is by no means exhaustive but serves as a good guide.

Safety First

Safety First

Electric vehicles are tested to the same high standards as other vehicles.

Do not touch any electric circuit that is greater than the standard 12 V or 24 V.

Table 2.1 Risks and their reduction

18

Identified risk

Reducing the risk

Electric shock 1

Voltages and the potential for electric shock when working on an EV mean a high risk level – see Section 2.2 for more details.

Electric shock 2

Ignition high tension (HT) is the most likely place to suffer a shock when working on an ICE vehicle; up to 40,000 V is quite normal. Use insulated tools if it is necessary to work on HT circuits with the engine running. Note that high-voltages are also present on circuits containing windings due to back EMF as they are switched off; a few hundred volts is common. Mainssupplied power tools and their leads should be in good condition, and using an earth leakage trip is highly recommended. Only work on HEV and EVs if trained in the high-voltage systems.

Battery acid

Sulfuric acid is corrosive, so always use good personal protective equipment. In this case, overalls and, if necessary, rubber gloves. A rubber apron is ideal as are goggles if working with batteries a lot.

Raising or lifting vehicles

Apply brakes and/or chock the wheels when raising a vehicle on a jack or drive-on lift. Only jack under substantial chassis and suspension structures. Use axle stands in case the jack fails.

Running engines

Do not wear loose clothing; good overalls are ideal. Keep the keys in your possession when working on an engine to prevent others starting it. Take extra care if working near running drive belts.

Exhaust gases

Suitable extraction must be used if the engine is running indoors. Remember it is not just the carbon monoxide that might make you ill or even kill you; other exhaust components could cause asthma or even cancer.

Moving loads

Only lift what is comfortable for you; ask for help, if necessary, and/or use lifting equipment. As a general guide, do not lift on your own if it feels too heavy!

Short circuits

Use a jump lead with an in-line fuse to prevent damage due to a short when testing. Disconnect the battery (earth lead off first and back on last) if any danger of a short exists. A very high current can flow from a vehicle battery; it will burn you as well as the vehicle.

Fire

Do not smoke when working on a vehicle. Fuel leaks must be attended to immediately. Remember the triangle of fire: Heat – Fuel – Oxygen. Don’t let the three sides come together.

Skin problems

Use a good barrier cream and/or latex gloves. Wash skin and clothes regularly.

2  Safe working, tools and hazard management 2.2 High-voltage safety precautions 2.2.1  Introduction In this section we will consider the differences between AC and DC as well as high and low voltages. This can be confusing, so let’s keep it very simple to start with: The voltages (AC or DC) used on electric vehicles can kill, have killed and will kill again. Follow all safety procedures and do not touch any electric circuit that is greater than the standard 12 V or 24 V that we are used to, and you will be fine!

2.2.2  Low and high-voltage Low-voltage is a relative term, the definition varying by context. Different definitions are used in electric power transmission and distribution and in the electronics industry. Electrical safety codes define low-voltage circuits, which are exempt from the protection required at higher voltages. These definitions vary by country and specific code. The International Electrotechnical Commission (IEC) define voltages as in Table 2.2. Definition

Figure 2.6  Plasma trails due to high-voltage

states: ‘High-voltage’ means the classification of an electric component or circuit if its working voltage is > 60 V and ≤ 1500 V DC or > 30 V and ≤ 1000 V AC root mean square (rms). Safety First For EVs, DC voltages between 60 V and 1500 V are referred to as ‘high-voltage’.

2.2.4  Personal protective equipment (PPE) In addition to the normal automotive-related PPE, the following are also recommended for work on high-voltage systems:

IEC: International Electrotechnical Commission.

2.2.3  Defining high-voltage For EVs, the United Nations (UN) document: Addendum 99: Regulation No. 100 Revision 3,

X overalls with non-conductive fasteners X electrical protection gloves X protective footwear with rubberised soles and non-metallic protective toe caps X goggles/face shield (when necessary)

Table 2.2  IEC voltages IEC voltage range

AC

DC

Defining risk

High-voltage (supply system)

>1000 Vrms*

>1500 V

Electrical arcing

Low-voltage (supply system)

50–1000 Vrms

120–1500 V

Electrical shock

Extra low-voltage (supply system)

600 V where it is unmatched, though gallium nitride (GaN) technology is catching up and providing a compelling alternative for applications 10%/day but 1,000 if air removed very low

10 min

Sodium-sulphur

100

150

200

2

Very good

0.06

300–350

Quite low if kept warm

8

Hydrogen fuel cell

400

650

0.3–0.9 (1.23 open circuit)

Super-capacitor

1–10

1,000–10,000

Seconds

Flywheel

1–10

1,000–10,000

Seconds

1,000

Recharge time (h)

Amp-hour efficiency

Operating temperature (°C)

Nominal cell voltage (V)

54–95

Energy density (Wh/I)

20–35

Specific energy (Wh/kg)

Lead-acid

Battery type

Specific power (W/kg)

Internal resistance (Ohms)

Table 5.2  Voltages and energy densities of batteries and storage devices (estimated for purposes of comparison)

5 Batteries

n/a

123

5 Batteries kilogram. This is a measure of the power it will supply and for how long per kilogram.

5.3  Battery technologies 5.3.1  Ambient temperature A study a few years ago by the American Automobile Association (AAA)1 showed that the impact of temperature on EVs is significantly more than was expected. The organisation tested five models: X BMW i3 X Chevrolet Bolt EV X Nissan LEAF X Tesla Model S X Volkswagen e-Golf Each car was operated at −7 °C and 35 °C. All had a similar response and, on average, lost about 12% range at the low temperature. This was a quite small loss but did not include the use of any cabin heating. When HVAC systems were activated, the range loss averaged 41%. This did not include seat or steering wheel heaters or headlights, which would impact the range further. Focused on two EVs2: X Tesla Model 3 with a 310-mile range rating X Nissan LEAF with a 151-mile range rating Testing was done on a track when the outside temperature averaged between −18 °C and −12 °C. The Tesla used up the equivalent of 121 miles to cover 64 actual miles, leaving a displayed range remaining of 189 miles. The Nissan used 141 miles of stated range to travel 64 miles, leaving just 10 miles showing on its range display. Lithium-ion battery components develop increased resistance at low temperatures, and this limits how much power they can hold as well as how fast they can be charged or discharged.

5.3.2  Battery temperature

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Electrical current flow in battery cells and the associated connections causes heat, so

Figure 5.23  Lithium-ion battery pack

cooling is, therefore, vital. This heating effect is proportional to the square of the current flowing multiplied by the internal resistance of the cells and connections (I2R). Internal resistance of the cells rises when cold. Many lithium battery cells should not be fastcharged when their temperature is below 0 °C. Battery management systems can handle this low temperature issue, but lithium cells also begin to degrade quickly if their temperature is too high (typically over 45 °C), and there are safety concerns with operation at high temperatures. Key Fact Many lithium battery cells should not be fast-charged when their temperature is below 0 °C. The temperature of cells also needs to be kept constant across the pack. Uneven temperatures can lead to degraded performance and potential thermal events (Figure 5.24). For efficient liquid cooling, there are two options: X indirect cooling using a liquid that is pumped around the battery and passed through a cooler radiator or similar X direct immersion cooling where the battery cell components are covered in a cooling agent

5 Batteries Direct liquid cooling/heating is more effective and takes up less volume provided that the heat transfer fluid is a safe and stable dielectric. Direct immersion cooling offers a safe, efficient, simplified design that enables more compact packaging. Key Fact Direct liquid cooling/heating is more effective and takes up less volume provided that the heat transfer fluid is a safe and stable dielectric. Figure 5.24  Representation of heat generated inside a battery pack (the penguin effect!)

Cooling the battery with a dielectric oil (the cooling agent) which is then pumped out to a heat exchanger system is an effective solution and offers good control. Figure 5.25 shows an example of this. Currently, the most widely used cooling approach is the indirect cooling method using a traditional cooling agent. As the demand of energy volumetric density, safety and power density increases, there is an urgent need for a safer, more efficient cooling system design and cooling agents. Direct immersion cooling is the safe recommendation.

Selection of the liquid for direct immersion cooling of electronics mustn’t be made on the basis of heat transfer characteristics alone. Chemical compatibility of the coolant with the cells, electronics (control units) and other packaging materials must be a prime consideration to help avoid X short circuits X corrosion X cross contamination X flammability risk There are several materials factors to be considered for fast charge of cells, because fast charging has four main limiting factors: X lithium plating X particle cracking X atomic rearrangement X temperature rise These four main factors must be taken into consideration when determining the optimal fast charge profile. If this is not done, then significant reduction in cell capacity will be the result. Increasing the charging time by changing cell chemistry or design will have a cost to either lifetime or energy density.

Figure 5.25  Battery pack with coolant flow connections (Source: Porsche Media)

Claimed charging times on some new battery designs vary from a few minutes to a few hours. The more ambitious fast charge times would have to overcome significant barriers to become a reality. As a bare minimum, a highly efficient thermal management system and detailed attention to component packaging is needed.

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5 Batteries

Figure 5.26  Gap fillers can have a huge impact on thermal conditions in a lithium-ion battery (Source: Solvay) The use of dielectric fluid as a cooling medium enables the battery to have a higher power capability than the original design. This higher power capability allows for faster charging times, reducing the charge time from 2 hours to less than 30 minutes. This is particularly important as the expectations for electric vehicles have shifted towards larger batteries and higher performance, making faster charging essential.

Furthermore, the immersion cooling technology has demonstrated its ability to prevent fires, highlighting its superior safety features compared to traditional cooling systems.

The immersion cooling technology, which was tested on a Volvo XC60 plug-in hybrid by TotalEnergies and Ricardo, offers several advantages. It improves efficiency, safety and performance while also extending battery life and reducing costs and risks for vehicle manufacturers. Importantly, the immersion cooling system can be integrated into existing vehicle architectures without requiring significant modifications.

Overall, the use of immersion cooling technology in mass-produced vehicles is a significant development that offers advantages in terms of faster charging, improved performance, increased safety and reduced costs.

By utilising immersion cooling, the battery’s thermal management is enhanced, resulting in faster charge times and improved overall performance. This advancement contributes to making electric vehicles more attractive to consumers by providing better performance, increased safety and reduced costs.

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In addition to the performance and safety benefits, immersion cooling can also lead to weight and cost reductions for vehicles. Through a simpler design and the use of lighter materials, the battery cost can be reduced by approximately 6%, resulting in a lighter overall vehicle.

Figure 5.27  Battery pack (Source: Ricardo)

5 Batteries 5.3.3  Thermal runaway Lithium-ion batteries can, if overheated, go into a thermal runaway process. This can be separated into three stages (Figure 5.28). An exothermic reaction increases the battery temperature and, therefore, the internal pressure of the Li-ion battery. Gas evolution also increases the pressure of the cell. If the cell is equipped with a pressure relief valve (not found on pouch cells), this valve will open and release flammable organic compounds. A pouch cell may burst if internal pressure is too high. Emission of organic carbonates can be seen as white smoke. During further heating of the cell, the colour of the smoke turns into grey by emitting active electrode material (mainly graphite particles). This thermal runaway process heats the cell up to 700–1000 °C. This high temperature may affect adjacent cells and cause a chain reaction. With the organic solvent, the conducting salt, LiPF6, is also emitted and reacts as follows:

Safety First An exothermic reaction increases the battery temperature and, therefore, the internal pressure of the Li-ion battery. X When heated in dry environments, the salt decomposes. X In contact with water/air moisture, toxic hydrogen fluoride (HF) gas is created. If a thermal runaway occurs, a large number of different kinds of chemicals are generated. Combustion reactions mainly create X CO, CO2 from organic materials X NOx, HF X low molecular weight organic acids, aldehydes, ketones Although a Li-ion battery fire should not normally be extinguished with pure water, using plenty of water may be reasonable because it cools the surrounding cells to avoid a following process. Additionally, many of the emitted particles and toxic gaseous compounds will bind and be diluted by water.

5.3.4  Solid-state batteries Bosch and many others are working on a new battery technology for electric cars that could be production-ready in the near future. Solidstate cells could be a breakthrough technology as the batteries charge faster and are smaller than current technologies (figure 5.30).

Figure 5.28  Thermal runaway stages. The SEI (solid electrolyte interphase) layer is a component of lithium-ion batteries formed from the decomposition of materials associated with the electrolyte of the battery

With the new solid-state cells, there is the potential to more than double energy density and, at the same time, reduce the costs considerably further. A comparable electric car that has a driving range today of 150 km would be able to travel more than 300 km without recharging at a lower cost. Engineers are working on further refining the technology and, in doing so, making electromobility a more practical proposition. By 2025, the company forecasts that roughly 15% of all new cars built worldwide to have at least a hybrid powertrain.

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Figure 5.29  Battery harmful event flowchart

Figure 5.30  Potential of solid-state batteries for EVs (Source: Bosch Media) The performance of an energy storage device can be improved by various methods. For example, in cell chemistry, the material that the positive and negative poles (cathode and anode) are made of plays a major role.

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In current lithium-ion batteries, one of the reasons energy capacity is limited is because the anode consists, to a large degree, of graphite. Using solid-state technology means the anode can be made out of pure lithium,

5 Batteries which considerably increases storage capacity. In addition, the new cells function without ionic liquid, which means they are not flammable.

5.3.5  Swarm intelligence The older the batteries get, the lower their performance and capacity and the shorter the range of the vehicle. To help batteries last longer, Bosch is developing new cloud services that supplement the individual vehicle’s battery management systems. Smart software functions in the cloud continually analyse the battery status and take appropriate action to prevent or slow down cell aging. These measures can reduce the wear and tear on the battery, the most expensive component of an electric vehicle, by as much as 20%. Key Fact The older the batteries get, the lower their performance and capacity and the shorter the range of the vehicle. Real-time data gathered from the vehicle and its surroundings play a key role here. The cloud services use this data to optimise every single recharging process and to provide drivers with tailored driving tips on how to conserve battery power via the dash display. The aim is to optimise battery performance, thus benefiting both drivers and fleet operators within the ecosystem.

triggers. All battery-relevant data (e.g., current ambient temperature, charging habits) is first transmitted in real time to the cloud, where machine-learning algorithms evaluate the data. With these services, Bosch is not only offering a window into the battery’s current status at all times but enabling a reliable forecast of a battery’s remaining service life and performance to be made for the first time. Previously, it was not possible to make any accurate forecast of how quickly an electric vehicle battery would wear out. The smart software functions use of the swarm principle: the algorithms used for analysis evaluate data gathered from an entire fleet not just from individual vehicles. Swarm intelligence is the key to identifying more of the stress factors for vehicle batteries and to identifying them more quickly. The new insights gained into a battery’s current status enable Bosch to actively protect it against aging. To give one example: Fully charged batteries age more quickly at particularly high or low ambient temperatures. Bosch’s cloud services thus ensure that batteries are not charged to 100% when conditions are too hot or too cold. By reducing the battery charge by only a few percentage points, the battery is protected against inadvertent wear and tear.

According to experts, the average service life of today’s lithium-ion batteries is 8 to 10 years or between 500 and 1,000 charge cycles. Battery makers usually guarantee mileage of between 100,000 and 160,000 km. However, rapid battery charging, high numbers of charge cycles, an overly sporty driving style and extremely high or low ambient temperatures are all sources of stress for batteries, which makes them age faster. Bosch’s cloud-based services are designed to recognise – and counter – these stress

Figure 5.31  Charging data is collected in the cloud (Source: Bosch Media)

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Figure 5.32  A charging strategy based on the cloud data means optimum charging strategies can be used (Source: Bosch Media)

Data in the cloud will also help improve battery maintenance and repair. As soon as a battery fault or defect is identified, for example, the driver or fleet operator can be notified. This increases the chances that a battery can be repaired before it becomes irrevocably damaged or stops working altogether. Finally, the cloud services also optimise the recharging process itself. Key Fact Data in the cloud will also help improve battery maintenance and repair. The recharging process is where there is a risk that the battery cells will permanently lose some of their performance and capacity. Smart software in the cloud can calculate an individual charge curve for each recharging process, regardless of whether it takes place at home or elsewhere. This means the battery is recharged to the optimum level, helping conserve the cells. Existing apps with charge timers merely allow drivers to time the recharging process so that it is carried out when demand for electricity is low. Optimising both fast and slow charging and controling electricity and voltage levels during the recharging process, prolongs battery life.

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5.4  Research and development 5.4.1  Battery research The increasing demand for battery raw materials, driven by the rising registrations of electrified vehicles, has raised concerns about the extraction and availability of these materials. While lithium and cobalt have been the subject of criticism for years due to ethical and environmental concerns, recent headlines have focused on the raw material nickel. The desire for a secure supply, cost reduction and the ethical sourcing of materials has led to ongoing changes in the composition of cell chemistry in batteries. Currently, lithium-ion battery technology is predominantly used in electric cars, but this term encompasses a wide range of possible material combinations. The choice of battery raw materials has a significant impact on the storage capacity, safety, thermal stability and service life of the battery cell. However, the challenge lies in finding the right balance between technical feasibility and accommodating overriding political factors when determining the battery composition. Adapting the composition of batteries to address political considerations is a complex task that requires careful evaluation of various factors, including performance, cost, availability and environmental and ethical concerns.

5 Batteries As the demand for electrified vehicles continues to grow, it is important for industry stakeholders to work towards sustainable and responsible sourcing of battery raw materials, explore alternative material options and invest in research and development to improve the efficiency and performance of batteries. Additionally, efforts to diversify supply chains and reduce dependence on specific regions can help mitigate potential disruptions caused by geopolitical events. Lithium ions migration from the anode to the cathode during battery discharge and the reverse process during charging. The active

materials in the electrodes play a crucial role in this ion insertion process. On the anode side, graphite is commonly used as the active material due to its ability to intercalate lithium ions. In some cases, silicon is added to graphite to enhance its performance. Both graphite and silicon are considered noncritical materials because they are widely available. On the cathode side, there are various material compositions that can be used. Two common examples are nickel manganese cobalt (NMC) oxides and nickel cobalt aluminium (NCA) oxides. These cathode materials contain the rare element cobalt, which has raised concerns

Figure 5.33  Battery cell elements3

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5 Batteries due to its limited availability and ethical sourcing issues. However, it’s important to note that there are ongoing efforts to reduce or eliminate the use of cobalt in battery chemistries. One alternative is the lithium iron phosphate (LFP) cathode, which is cobalt-free. LFP batteries have gained popularity, particularly in certain applications such as electric buses, where safety, long cycle life and cost-effectiveness are important considerations. The choice of cathode material in battery cells depends on several factors, including performance requirements, energy density, cost and availability of raw materials. The industry continues to explore new material combinations and chemistries to improve battery performance, reduce reliance on critical materials and address environmental and ethical concerns associated with raw material extraction. Overall, the selection of battery cell raw materials is a complex process that involves balancing performance, availability, sustainability and cost considerations. The use of lithium in batteries is not a coincidence but, rather, a result of its exceptional properties that make it well-suited for this application. Lithium is the lightest solid element, with a very low molar mass of 6.94 g/mol. This low mass contributes to the gravimetric energy density of batteries. Despite the fact that battery systems in electric vehicles (BEVs) weigh several hundred kilograms, the amount of lithium used typically ranges from 5 to 15 kg. This means that lithium can store a significant amount of energy relative to its weight. Additionally, lithium’s small ionic radius of 76 pm, derived from its position in the periodic table, is beneficial for the volumetric energy density of batteries. The compact size of lithium ions allows for efficient packing within the battery, increasing the amount of energy that can be stored in a given volume.

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Furthermore, lithium has the most negative normal potential (-3.04 V) among all elements according to the electrochemical series. This

means that lithium can achieve a high cell voltage, which is advantageous for battery performance. The high cell voltage contributes to the overall energy density of lithium batteries. As a result of these characteristics, lithium enables batteries to achieve high energy densities of 250 Wh/kg and above. This high energy density is crucial for the efficient storage and delivery of electrical energy, making lithium an excellent choice for battery applications, particularly in the context of electric vehicles and portable electronics. It’s important to note that other factors, such as battery chemistry, cell design and manufacturing processes, also play significant roles in determining the overall performance of lithium batteries. Ongoing research and development efforts are focused on further improving the energy density, safety and cost-effectiveness of lithium-based battery technologies. Researchers are exploring alternatives to lithium-based batteries to reduce dependence on lithium and improve cost-effectiveness. One such alternative is the sodium-ion battery (SIB). Sodium, being in the same group as lithium in the periodic table, shares some similarities and represents a plausible alternative. Sodium is more abundant and, therefore, offers a cost advantage compared to lithium. Additionally, certain components of the battery, such as the copper current collector and electrolyte, can be replaced with cheaper alternatives without compatibility issues. However, it’s important to note that sodiumion technology also has significant drawbacks. The larger ionic radius of sodium leads to a reduced volumetric energy density compared to lithium, and it causes significant volume changes (known as breathing) during cell operation due to ion storage and removal at the electrodes. Furthermore, finding suitable materials for the anode in sodium-ion batteries is challenging, as graphite, commonly used in lithium-ion batteries, cannot be used. While there are promising developments in lithium-free battery technologies, they are

5 Batteries currently mostly research topics or niche products. It will take time for these alternatives to gain significant market share and overcome the dominance of lithium-ion technology. Even the solid-state battery, often considered as a potential successor to lithium-ion, is still based on lithium chemistry. According to experts, lithium-ion technology is expected to continue dominating the market for many years to come. However, ongoing research and development efforts in both lithium-based and lithium-free battery technologies are focused on improving energy density, safety, cost-effectiveness and sustainability to meet the evolving needs of various applications.

5.4.2  Toyota 1500 km battery Toyota is currently in the process of developing advanced battery technology that they claim will significantly enhance the range of future electric vehicles (EVs) to an impressive 932 miles (1,500 km). As part of its forthcoming EV plans, the automaker has announced its commitment to achieving a ground-breaking improvement in battery performance within the next five years. By 2026, Toyota intends to introduce new battery technology that will offer an extended range of 1,000 km (621 miles) through enhanced energy density, weight reduction and improved vehicle aerodynamics. They also aim to reduce costs by 20% compared to the current model while achieving a quick charging time of 20 minutes or less for a 10–80% power charge. Toyota is also working on the development of affordable batteries that will contribute to the wider adoption and expansion of battery electric vehicles (BEVs). One such innovation is the implementation of a bipolar structure battery, which has already been utilised in the Aqua and Crown hybrid vehicles and will now be applied to BEVs. This battery utilises lithium iron phosphate (LFP) and is anticipated to be available between 2026 and 2027. This low-cost battery is projected to offer a 20% increase

in range compared to their current model (approximately 375 miles), with a significant 40% reduction in cost and a recharge time of 30 minutes or less (10–80% charge). However, the real game-changer on the horizon is the development of all-solid-state batteries, which have the potential to revolutionise the distance that Toyota vehicles can travel on a single charge. Overcoming the long-standing challenge of battery durability, Toyota has made a technological breakthrough and is actively exploring its implementation in conventional hybrid electric vehicles (HEVs) while expediting its application in BEVs. The company is currently focused on developing a mass production method, with plans to commercialise the technology between 2027 and 2028. This all-solid-state battery technology is expected to deliver a 20% improvement in range compared to the previously announced 1,000 km range, along with an even faster charging time of 10 minutes or less (10–80% charge). As a result, Toyota’s BEVs could potentially achieve a remarkable range of up to 1,200 km (745 miles). In tandem with these advancements, Toyota is also working on a higher-level specification battery that aims to provide an extraordinary 50% increase in range, pushing the boundaries to a remarkable 1,500 km (932 miles). These are great ambitions and Toyota does have a great history of innovation. But, as with all claims about amazing new battery technologies, we will have to wait and see.

5.4.3  Fire detection The development of a new battery safety sensor by Metis Engineering aims to address the limitations of existing battery management systems (BMS) in detecting potential battery failures and preventing catastrophic incidents in electric vehicles. The Production Battery Safety Sensor is designed to monitor battery health beyond what a BMS can achieve. The sensor, which is currently in the beta version, is capable of detecting cell venting

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5 Batteries within seconds, providing early detection of thermal runaway and allowing more time for vehicle evacuation. It collects data on various environmental parameters such as volatile organic compounds (VOCs), pressure change, humidity, dew point and optional accelerometer readings to record shock loads. By analysing this data, including crossreferencing with cell temperatures, the sensor can identify cell-venting events. The sensor is integrated into the vehicle’s electrical system using a CAN interface and is placed inside the battery pack to “sniff the air” for VOCs emitted during cell venting. It relays the collected data to a control unit, such as the vehicle’s electronic control unit (ECU), which can alert the driver and initiate safety measures, such as cutting off the circuit to the battery pack to prevent thermal runaway. While existing BMS systems already monitor battery temperature and voltage changes, they have limitations in detecting cell issues in a timely manner. Temperature sensors in BMS are typically placed at certain points within the pack, and if a cell is located far from the sensor, it may not detect temperature changes in time. Voltage fluctuations can also be challenging to interpret due to the influence of other cells in parallel. The new battery safety sensor offers an additional layer of protection by providing

more comprehensive monitoring of battery health and early detection of potential failures. It is currently being tested by several electric vehicle original equipment manufacturers (OEMs) and battery manufacturers. Thermal runaway in battery cells is a complex process that can lead to catastrophic failures if not properly managed. The stages of thermal runaway involve temperature increase, pressure buildup, venting and the potential for a self-oxidising reaction that can result in a fire and further propagation of the failure. The sensor addresses these risks by monitoring key parameters and providing early warnings. By detecting temperature increases, the sensor can identify when a battery cell is becoming overheated, which can be caused by factors like excessive workload, manufacturing defects or aging. The rise in temperature leads to pressure buildup inside the cell, and if the pressure exceeds a certain threshold, venting occurs. To further enhance safety, the optional accelerometer in the sensor enables the monitoring of shock loads and impact duration that the battery pack may experience during a collision. This information can help assess the condition of the battery pack and inform decisions regarding servicing, repurposing for energy storage systems, recycling or insurance claims. Another important aspect monitored by the sensor is the dew point within the battery pack. Cooling systems are typically used to prevent overheating, but if the cooling is too effective and lowers the temperature below the dew point, condensation can occur, leading to potential shorting and thermal incidents. By monitoring the dew point, the sensor can provide a warning before condensation settles on the battery terminals.

Figure 5.34  Battery safety sensor (Source: Metis)

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Overall, this battery safety sensor aims to detect early signs of thermal runaway, such as temperature increases, pressure changes, shock loads and dew point variations. By providing timely warnings, it helps mitigate

5 Batteries the risks associated with battery failures and enables appropriate preventive actions to ensure the safety and longevity of the battery pack.

5.4.4  Leading edge (lithium-air) Scientists and engineers at Argonne, a technology research company, have announced a ground-breaking achievement in battery technology (Figure 5.35). They claim to have successfully developed a revolutionary battery with an energy density four times higher than traditional lithium-ion batteries (in the lab). This remarkable advancement means that electric vehicles (EVs) could potentially travel over a thousand miles (1600 km) on a single charge, and in the future, the battery could also power domestic planes and long-distance trucks. The key innovation in this lithium-air battery lies in the use of a solid electrolyte instead of the conventional liquid electrolyte. The researchers assert that the lithium-air battery exhibits the highest projected energy density among all battery technologies currently being explored for the next generation beyond lithium-ion. Previous lithium-air designs, where lithium from a lithium metal anode moved through a liquid electrolyte to combine with oxygen during discharge, resulted in the formation of lithium peroxide (Li2O2) or superoxide (LiO2) at the cathode. This solid ceramic polymer electrolyte (CPE) is composed of a material made from cost-effective nanoparticle elements. Its introduction enables chemical reactions that generate lithium oxide (Li2O) upon discharge. The chemical process involving lithium superoxide or peroxide only requires the storage of one or two electrons per oxygen molecule, whereas lithium oxide necessitates the storage of four electrons.

Figure 5.35  Lithium-air battery (Source: Argonne) Through further refinement and development, Argonne anticipates that the lithium-air battery could achieve an unprecedented energy density of 1200 Wh/kg, four times better than existing lithium-ion batteries. To provide context, Tesla’s latest 4680 cells, known for their high energy density, range between 272–296 Wh/kg.

5.4.5  Obituary Battery science lost a giant in June 2023. Just at the point of completing the script for this book we heard the news that Nobel prize–winning scientist Professor John Goodenough (born in 1922) had died. He is credited as the father of the lithium-ion battery. Our respect and admiration. Learn more about his achievements at https:// en.wikipedia.org/wiki/John_B._Goodenough

Notes 1 AAA: (the American Automobile Association, Inc.) https://www.aaa.com.4 Consumers Union: https://www.consumersinternational.org 2 Another study, conducted by Consumers Union. 3 Schmalz, M., Wagner, A., Lichtblau, F. et al. Range, Safety, Service Life - Battery Raw Materials and Their Technical Relevance. ATZ Electron Worldw 17, 8–13 (2022).

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6

CHAPTER

Motors and control systems 6.1 Introduction 6.1.1  Types of motor There are several choices for the type of drive motor, the first being between an AC or DC motor. The AC motor offers many control advantages but requires the DC produced by the batteries to be converted using an inverter. In much earlier systems, a DC shunt-wound motor rated at about 50 kW was a popular choice for smaller vehicles, but AC motors are now the most popular. Actually, the distinction is blurred. The drive motors can be classed as AC or DC, but it becomes difficult to describe the distinctions between an AC motor and a brushless DC motor. Key Fact The AC motor offers many control advantages but requires the DC produced by the batteries to be converted using an inverter.

6.1.2  Trends The three-phase AC motor with a permanent magnet rotor is the choice for

most manufacturers. This is because of its efficiency, size, ease of control and torque characteristics. It is powered by DC ‘pulses’. This type is sometimes described as an electronically commutated motor (ECM).

6.2 Construction and function of electric motors 6.2.1  AC motors: basic principle In general, all AC motors work on the same principle. A three-phase winding is distributed around a laminated stator and sets up a rotating magnetic field that the rotor follows. The general term is an AC induction motor. The speed of this rotating field and, hence, the rotor can be calculated: n = 60

f p

where n is speed in rpm, f is frequency of the supply and p is the number of pole pairs.

6.2.2  Asynchronous motor The asynchronous motor is often used with a squirrel-cage rotor made up of a number of pole pairs. The stator is usually three-phase and can be star or delta wound. The rotating DOI: 10.1201/9781003431732-6

6  Motors and control systems magnetic field in the stator induces an EMF in the rotor, which, because it is a complete circuit, causes current to flow. This creates magnetism, which reacts to the original field caused by the stator, and, hence, the rotor rotates. The amount of slip (difference in rotor and field speed) is about 5% when the motor is at its most efficient.

Three-phase supply

Rotor windings

Stator windings

Key Fact An asynchronous motor is often used with a squirrel-cage rotor.

Figure 6.2  Representation of the synchronous motor

6.2.3  Synchronous motor: permanent excitation This motor has a wound rotor, known as the inductor. This winding is magnetised by a DC supply via two slip rings. The magnetism ‘locks on’ to the rotating magnetic field and produces a constant torque. If the speed is less than n (see previous section), fluctuating torque occurs and high current can flow. This motor needs special arrangements for starting Three-phase supply

rotation. An advantage, however, is that it makes an ideal generator. The normal vehicle alternator is very similar. Key Fact A synchronous motor has a wound rotor known as the inductor.

6.2.4  DC motor: series wound

Stator windings

Squirrel cage rotor

Figure 6.1  An asynchronous motor is used with a squirrel-cage rotor made up of a number of pole pairs

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Brush and slip rings

The DC motor is a well-proven device and was used for many years on electric vehicles such as milk floats and forklift trucks. Its main disadvantage is that the high current has to flow through the brushes and commutator. The DC series-wound motor has well-known properties of high torque at low speeds. Figure 6.3 shows how a series-wound motor can be controlled using a thyristor and also provide simple regenerative braking. Key Fact The DC series-wound motor has wellknown properties of high torque at low speeds and is ideal as a starter motor.

6  Motors and control systems 6.2.5  DC motor: separately excited shunt wound

Thyristor operated from drive controller

Driving

The fields on this motor can be controlled either by adding a resistance or using chopper control in order to vary the speed. Start-up torque can be a problem, but with a suitable controller, this can be overcome. The motor is also suitable for regenerative braking by increasing field strength at the appropriate time. Some EV drive systems only vary the field power for normal driving, and this can be a problem at slow speeds due to high current.

D2 +

M

–

D1

Braking

D2 –

G

6.2.6  Electronically commutated motor

+

Brake switch

D1

Figure 6.3  A series-wound motor can be controlled by using a thyristor and can also provide simple regenerative braking

The electronically commutated motor (ECM) is, in effect, halfway between an AC and a DC motor. Figure 6.5 shows a representation of this system. Its principle is very similar to the synchronous motor, except the rotor contains permanent magnets and, hence, DC separately excited

DC series

Speed of rotation Synchronous PM

Asynchronous

Power

Torque

Power

Torque Speed of rotation

Power

Torque

Power

Torque Speed of rotation

Speed of rotation

Figure 6.4  Torque characteristics

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6  Motors and control systems Definition

Electronic control

BLDC: brushless DC motor.

Stator windings

N S

P.M. rotor

Hall Effect speed and position sensor

Figure 6.5  The EC motor is an AC motor no slip rings. It is sometimes known as a brushless motor. The rotor operates a sensor, which provides feedback to the control and power electronics. This control system produces a rotating field, the frequency of which determines motor speed. When used as a drive motor, a gearbox is needed to ensure sufficient speed of the motor is maintained because of its particular torque characteristics. Some schools of thought suggest that if the motor is supplied with square-wave pulses, it is DC and if supplied with sine-wave pulses, then it is AC. Definition ECM: electronically commutated motor. These motors are also described as brushless DC motors (BLDC), and they are effectively AC motors because the current through them alternates. However, because the supply frequency is variable, it has to be derived from DC, and its speed/torque characteristics are similar to a brushed DC motor, it is sometimes called a DC motor.

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It can also be called a self-synchronous AC motor, a variable-frequency synchronous motor, a permanent-magnet synchronous motor, or an electronically commutated motor (ECM) – I hope that’s clear and prevents any further confusion! However, it is now the motor used for the majority of EVs. The operating principle is shown in more detail in Figure 6.6. The rotor is a permanent magnet and the current flow through the coil determines the polarity of the stator. If switched in sequence and timed accordingly, the momentum of the rotor will keep it moving as the stator polarity is changed. Changing the switching timing can also make the rotor reverse. Overall, therefore, good control of the motor is possible. Key Fact The EC motor has a permanent magnet rotor. The switching must be synchronised with the rotor position, and this is done by using sensors, Hall Effect, in many cases, to determine the rotor position and speed. If three coils or phases are used, as shown next, then finer control is possible as well as greater speed, smoother operation and increased torque. Torque reduces as speed increases because of back EMF. Maximum speed is limited to the point where the back EMF equals the supply voltage. Key Fact In any type of EC motor, supply switching must be synchronised with the rotor position. This is done by using position sensors.

6  Motors and control systems

Definition

S S

N N

Hall Effect: The production of a voltage difference across an electrical conductor, transverse to an electric current in the conductor and a magnetic field perpendicular to the current. This effect was discovered by Edwin Hall in 1879 and is used for sensing rotation speed and position.

(a)

A

N

C

S

N

S

B

Momentum keeps rotor moving

N

B

S

C

A (b)

Figure 6.7  Three coils (three-phases) improve on the basic principle. Many more coils are used on real machines (see Figure 6.8)

N S

N S

Two typical motors are shown in Figures 6.8 and 6.9, one is integrated with the engine flywheel and the other a separate unit. Both are DC brushless motors and are water cooled.

6.2.7  Switched reluctance motor

(c)

Figure 6.6  Principle of the DC brushless motor operation

The switched reluctance motor (SRM) is similar to the brushless DC motor. However, the major difference is that it does not use permanent magnets. The rotor is a form of soft iron and is attracted to the magnetised stator. The basic principle is shown in Figure 6.10 and an improved version in Figure 6.11.

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6  Motors and control systems

Magnetic field turns rotor to minimize air gap

(a)

on

Figure 6.8  Bosch integrated motor generator (IMG) also called integrated motor assist (IMA) by some manufacturers Momentum keeps rotor moving

off (b)

Magnetic field turns rotor to minimize air gap

Figure 6.9  Separate motor unit showing the coolant connections on the side and the three main electrical connections on top

Definition SRM: switched reluctance motor. Timing of the switching of the stator is again very important, but the key advantage is that no expensive rare earth magnets are needed. The raw materials for these are a source of political discussion, with China being the main supplier. Overall, the machine is very simple and, therefore, cheap. Early SRMs were noisy, but this has been solved by more accurate switching control.

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(c)

on

Figure 6.10  Basic principle of a switched reluctance motor

A company known as HEVT has developed a potentially game-changing alternative to induction and permanent magnet motors. These motors have a much reduced cost volatility due to the use of zero rare earth minerals. The company’s patented switched reluctance motors (SRMs) provide high-performance

6  Motors and control systems

A

C

B

B

C

A

Figure 6.12  Switched reluctance motor stator (left) and rotor (right) without windings on the stator (Source: HEVT)

Key Fact

(a)

Switched reluctance motors do not work well as generators because of a nonmagnetic rotor. A

C

B

B

C

A (b)

Figure 6.11  Improved SRM with additional poles (the rotor invariably has two fewer than the stator)

alternatives to induction and permanent magnet motor/generators. One product is being rolled out to provide electrical assist to eBikes, but current motor technology ranges from approximately 150 W scalable to 1 MW, and it is expected they may appear in some EVs soon. However, they do not work well as generators because of the nonmagnetic rotor.

The SRM control systems are similar to those for BLDC motors, but while they have slightly lower peak torque, their efficiency is maintained over a much wider speed and torque range. The SRM is effectively a powerful stepper motor.

6.2.8  Motor efficiency Motor efficiency varies with type, size, number of poles, cooling and weight. The designers are always striving to get more out of smaller, lighter packages. In general, the efficiency of a BLDC ranges from about 80% for a 1 kW motor to 95% for a 90 kW motor. Key Fact In general, the efficiency of a BLDC ranges from about 80% for a 1 kW motor to 95% for a 90 kW motor. Efficiency is the ratio between the shaft output power and the electrical input power. Power output is measured in watts (W), so efficiency can be calculated: p out / p in

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6  Motors and control systems where Pout = shaft power out (W) and Pin = electric power into the motor (W).

Figure 6.14. The four graphs show torque and power as functions of rotational speed.

The electrical power lost in the primary rotor and secondary stator winding resistance are also called copper losses. The copper loss varies with the load in proportion to the current squared and can be calculated:

The characteristics torque and power curves of a typical ECM car drive motor compared to an internal combustion engine are shown as Figure 6.14.

I 2R where R = resistance (Ω) and I = current (amp). Definition Motor efficiency is the ratio between the shaft output power and the electrical input power. Other losses include X iron losses: The result of magnetic energy dissipated when the motor’s magnetic field is applied to the stator core. X stray losses: The losses that remain after primary copper and secondary losses, iron losses and mechanical losses. The largest contribution to the stray losses is harmonic energies generated when the motor operates under load. These energies are dissipated as currents in the copper windings, harmonic flux components in the iron parts or leakage in the laminate core. X mechanical losses: The friction in the motor bearings, in the fan for air cooling or a pump if water or oil cooling is used.

Figure 6.13  Motor efficiency

6.2.9  Motor torque and power characteristics The torque and power characteristics of four types of drive motors are compared in

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6.2.10  Winding shapes and insulation Using higher voltages (700 V+) means thicker insulation is needed on the motor windings. Solvent-based insulators, such as varnish, are not adequate for the job. However, careful design and the use of new materials can result in three key benefits: X torque increase X power increase X size reduction Innovative developments in the way stator windings are created and insulated are resulting in significant improvements in efficiency. Electric motor stator windings were traditionally round copper wires beneath a protective layer of enamel or varnish. Changing from round wire to rectangular helps fill the available space as represented in Figure 6.15. When enamel is used as the insulator, it is very difficult to achieve the exact thickness required. Higher voltages require thicker insulation and/or insulation with a higher dielectric rating. Conventional motors generally use enamelled wire with a film thickness of 0.1 mm or less. This enamel provides adequate insulation between wires in a phase, but because of the higher potential difference between phases, insulating paper is added. It is not possible to increase the thickness of enamel coatings, so the enamelled magnet wire shown at the top in Figure 6.16 has been covered in extruded high-performance plastic (in this example Ketaspire© PEEK which is a polyetheretherketone resin). The wire at the bottom in Figure 6.16 is using PEEK and no enamel.

6  Motors and control systems

Figure 6.14  ECM and ICE torque and power curves

Figure 6.15  Rectangular windings make more efficient use of the available space, even with similar or increased thickness of insulation This insulation can be applied in even thickness for predictable performance, and it has favourable adhesion to metals. Extrusion can be used in round, square and rectangle profiles, which enables motor designers to optimise the slot fill. Extrusion provides the added benefit of being a more efficient manufacturing process versus solvent-based coatings.

6.2.11  Axial and radial windings In motors where the windings are made from separate segments, there are two main ways that the windings are positioned, axially as if wound around a shaft parallel to the axle, and radially as if wound around a radius of the central shaft (Figure 6.17). A U.K. company YASA was founded on an innovative approach to the design and

Figure 6.16  Enamel and/or extruded resin on a wire manufacture of electric motors and controllers. In its motors, the windings consist of separate segments ideally suited to mass manufacture with minimal application engineering. Figure 6.18 shows a motor with axial windings. The axial flux approach uses less materials such as copper, iron and permanent magnet than conventional motors, resulting in a significantly lower materials cost. The other key benefit is that these axial flux motors are smaller and lighter than any other motors in their class due to the more efficient use of key magnetic and structural materials. The

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6  Motors and control systems of up to 10 kW/kg and torque densities that are significantly better than the nearest competitive motor topology. The axial flux enables high power densities to be achieved at relatively low speeds (2000–9000 rpm), making the motors ideally suited to hybrid and generation applications. Figure 6.17  Radial (left) and axial (right) motor design

6.2.12  Drive motor developments and case studies Infinitum Infinitum has made significant advancements in motor technology with their recent achievement of a 50% smaller and lighter axialflux motor. This has been made possible by replacing the traditional iron core and copper windings with a printed circuit board (PCB) stator, which incorporates etched copper conductors. This innovative design eliminates core losses, such as torque ripple, cogging, stator hysteresis and eddy currents, resulting in a motor with higher overall efficiency.

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Figure 6.18  YASA axial electric motor, 260 Nm/180 kW 10 s peak, 65 mm length, 260 mm diameter, 12 kg, 15 W/kg (Source: YASA)

In addition to its smaller and lighter form, the motor incorporates a liquid-cooling system that directly channels coolant to the motor’s heat source. The coolant is injected into a hollow shaft and released over the entire area of the stator. This cooling method enables four to five times the power density compared to traditional radial-flux motors. Unlike other cooling methods that only provide a coolant jacket around the motor, Infinitum’s system ensures that coolant reaches the centre of the stator. Centrifugal force then pushes the liquid to an outer jacket, where it drains into a sump for recirculation.

yokeless and segmented armature (YASA) motor topology also significantly reduces manufacturing complexity, making the motors ideally suited to automated volume production. The YASA 750, YASA P400 Series and YASA 400 axial flux motors achieve power densities

The resulting motor boasts impressive performance metrics, with a continuous power output of 150 kW (201 hp) and a peak power output of 300 kW (402 hp). It operates with 95% efficiency at 7500 RPM. Additionally, the motor is capable of receiving over-the-air updates, allowing for potential optimisations and enhancements in the future.

6  Motors and control systems

Figure 6.19  An exploded look at Infinitum’s motor shows its exceptionally thin PCB stators (Source: Infinitum)

DeepDrive DeepDrive is a startup focused on developing a dual-rotor electric motor to enhance the range of electric vehicles (EVs) in a costand resource-efficient manner. Their radial flux dual-rotor motor incorporates power electronics and is designed to be highly flexible, allowing for installation in various vehicle configurations, such as central drive or in-wheel drive systems. One of the key aspects of DeepDrive’s technology is its patented design, which not only extends the range of EVs but also offers a high-torque density. The motor’s manufacturing process is cost-effective and utilises fewer natural resources, leading to a reduced environmental impact compared to traditional motors. DeepDrive’s electric motors boast high efficiency and provide significant benefits in terms of weight, cost and space. They are poised to enable the development of the next generation of efficient and resource-saving electric vehicles. Furthermore, the design of DeepDrive’s e-motor technology aims to facilitate easy and costeffective mass production.

Figure 6.20  BMW DeepDrive (Source: BMW Media)

Audi liquid cooled motors In the Audi e-tron electric vehicles, the asynchronous motors utilise lightweight rotors with in-casted aluminium squirrel cages.

Figure 6.21  Operating principle of the Audi e-tron asynchronous motors: www.audimediacenter.com/en/audimediatv/video/audi-etron-electromagnetics-e-engine-animation-4843

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6  Motors and control systems These motors operate based on the principle of induction, where the current in the copper windings of the stator generates a rotating magnetic field that interacts with the rotor. The rotor, which consists of the aluminium squirrel cage, always rotates slightly slower than the rotating field of the stator. This speed difference causes a current to be induced in the squirrel cage. As a result, a magnetic field is created in the rotor, which closes via the stator. This magnetic field exerts a circumferential force on the rotor, ultimately causing it to rotate. The animation demonstrates how the pulsating three-phase alternating current (AC) from the power electronics generates the rotating magnetic field necessary for motor operation. In the Audi e-tron 55, this motor configuration is employed in the front e-axle, providing a maximum torque of up to 309 Nm. In the sporty Audi e-tron S, the twin rear e-axle features two of these motors, combining to deliver a maximum torque of up to 618 Nm. The power electronics (PE) is one of the most important components of an e-axle. It converts the DC current from the battery into AC current for the motor. The pulsating three-phase current with variable frequency and amplitude generates a rotating magnetic field in the stator of the motor, which causes the rotor to turn. In case of the Audi e-tron, all functions needed to drive the motor are packed into this small box: X size: 5,5 l X weight: 8 kg X voltage level 150 V – 460 V

Figure 6.23  Cooling and heat dissipation of the twin-coax drive: www.audi-mediacenter. com/en/audimediatv/video/e-tron-twin-motoranimation-water-cooling-5066 X max. current: 530 A X power density: 30 kW/l The power density of power electronics and electric motors will continue to increase. The animation shows the Audi e-tron 55 front e-axle with power electronics, motor and gearbox and focuses on the effective cooling concept with rotor internal cooling. The rear e-axle with coaxial architecture has a watercooled rotor shaft.

6.3  Control system 6.3.1  Introduction Figure 6.24 shows a generic block diagram of a PHEV. Remove the AC mains block, and it becomes an HEV, or remove the internal combustion engine (ICE), and it becomes a pure EV. The control components are outlined in the next sections. These are microprocessor control units that are programmed to react to inputs from sensors and from the driver.

6.3.2  Basic operation

Figure 6.22  Technology of electric drives: www.audi-mediacenter.com/en/audimediatv/ video/audi-e-tron-power-electronics-e-engineanimation-4845

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To operate the motor, different phases are switched on at different times to cause rotation. The signals used to switch the transistors (usually IGBTs) are pulse-width modulated for finer control. The basic sequence is shown as Figure 6.25. This process is examined in more detail later, but first we need to examine the stages before motor control takes place.

6  Motors and control systems

IC Engine

Mains

Mechanical Linkage

AC Electrical

Generator

DC Electrical Subsystem DC-DC Converter

Rectifier

DC Current Sensing

12/24/42 V DC Subsystems

Regenerative Braking Power Conversion

AC Motor

Wheels

Regenerative DC-DC Converter

Mechanical Propulsion Traction Motor

DC Current Sensing Battery

Inverter

AC Current Sensing

Figure 6.24  EV block diagram showing the main components Table 6.1  Main components Component

Purpose

Motor/generator

Provides drive to the wheels and generates electricity when the vehicle is slowing and braking

Inverter

A device to convert DC into AC

Rectifier

A device to convert AC into DC (the inverter and the rectifier are usually the same component)

DC–DC converter: regenerative

This converts the AC from the motor during braking after it has been rectified to DC. The conversion is necessary to ensure the correct voltage level for charging.

DC–DC converter: subsystem

A device to convert high-voltage DC into low-voltage DC to run the general vehicle electrics

DC subsystems

The 12 V (or 24/42 V) systems of the vehicle such as lights and wipers – this may include a small 12 V battery

Battery (high-voltage)

Usually lithium-ion or nickel–metal hydride cells that form the energy store to operate the drive motor

Battery control

A system to monitor and control battery charge and discharge to protect the battery as well as increasing efficiency

Motor control

Arguably the most important controller, this device responds to sensor signals and driver input to control the motor/generator during the various phases of operation (e.g., accelerating, cruising, braking)

Internal combustion engine

Internal combustion engine used on HEVs and PHEVs only – it hybrids with the motor. On a REV, the engine would drive a generator to charge the high-voltage battery only.

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6  Motors and control systems

Figure 6.25  Inverter switching operation and motor rotation

Figure 6.26  Simplified EV high-voltage circuit

6.3.3  Start up and shut down Electric and hybrid vehicles are switched on by turning the key or pressing a button, just like ICE vehicles. However, the process that goes on behind the scenes is quite different. The description here is typical of most systems, but manufacturers do things in different ways so always check their information before assuming it is safe. Under normal operating conditions, the high-voltage system can be in four different conditions or modes: X off X start-up X ready X shutdown

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Figure 6.26 shows a simplified high-voltage system circuit that uses three relays (or contactors): X main + X main – X pre-charge Off: From the off position, the relays are operated in a defined sequence. Figure 6.27 shows this sequence and the system voltages. Start-up: When the vehicle is first switched on, the pre-charge contacts close for a short time and then open again. This allows tests to be carried out as no current should be flowing. Next the main negative contacts are closed; again, this allows circuit testing.

6  Motors and control systems

Figure 6.27  Start-up, ready mode and shutdown sequence contact positions and system voltages

The pre-charge contacts close again, and the capacitor starts to charge from the high-voltage battery through a resistor to limit the current. Finally, the main positive contacts are closed, the capacitor fully charges and the system is now described as being in Ready mode. The pre-charge feature is to protect the battery as well as allowing diagnostic functions. If the capacitor was connected immediately by the main contacts, it would charge very quickly and the sudden, albeit very short, battery discharge current would be massive and could damage the cells.

Key Fact The pre-charge feature is to protect the battery as well as allowing diagnostic functions. The main capacitor is responsible for keeping the voltage constant and for smoothing out any voltage peaks. It can have a rating in the region of 500 mF – which is a very high value, meaning it can store a lot of energy. Touching the capacitor is potentially more dangerous than the battery, but both can kill you quickly! Ready: The two main contacts remain closed and the vehicle can be used as normal.

‘Ready’, or similar, is normally displayed on the instrument panel. Shutdown: When the vehicle is switched off, the main positive contact is opened, and the capacitor starts to discharge. Once fully discharged, the system is considered to be off. The discharge happens in two different ways: X active X passive Active discharging functions by reducing the high-voltage to less than 60 V within four seconds. To do this, the transistors in the inverter are pulsed, which effectively discharges the capacitor through the motor windings. Active discharging is carried out in the event of X ignition off X in the event of a crash (belt tensioner or airbag triggered) X pilot line open In the event of a defective inverter, an emergency capacitor discharge is carried out using a discharge resistor, which takes about four seconds. Passive discharging is implemented with the aid of various resistors within the power and control electronics between high-voltage positive and high-voltage negative. This takes about 120 seconds, and it is carried out at all times.

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6  Motors and control systems On most systems, the transistors in the inverter are opened when the vehicle is being towed. If the ignition is off, the vehicle can be pushed at walking pace. If the ignition is on and the selector lever is set to the N position, then most vehicles can be towed at up to approximately 50 km/h. If the vehicle is pushed at a speed greater than walking pace when the ignition is off or is towed at a speed greater than approximately 50 km/h with the ignition on, the transistors switch to active short circuit. The three phase lines U, V and W are shortcircuited by closing the transistors. The electric drive motor can then only be rotated with a very high mechanical resistance. If the vehicle is towed for an extended period with an active short circuit, there is a risk of overheating.

6.3.4  High-voltage DC relays High-voltage DC (HVDC) relays are used to supply and cut off the DC power, by opening and closing contacts using an actuator. Arcing that occurs when the DC power is cut off may cause damage to the contacts and surrounding components, so the arc should be extinguished as quickly as possible in the desired direction. As an example, from the company LSIS, its HVDC relay range has excellent electrical durability, compact size, with low noise and features a permanent magnet and hydrogen inside for optimal arc

Figure 6.28  GPR-M series relays (Source: LSIS)

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extinguishing. Hydrogen is only flammable if oxygen is also present. Key Fact Arcing occurs when DC power is cut off, and this can cause damage to relay contacts. The company LSIS has been developing its 450 V devices and now have 1000 V and 1500 V relays. Generally, as the rated voltage increases, the size of the product must be increased to ensure insulation. However, the new series is implemented in the same size as the earlier types, thus improving the space utilisation. As the battery capacity of the vehicle increases, the rated voltage is increased and the external charge is expanded. Therefore, it is required to monitor the increase of the DC relay voltage and the on/off of the contact point. The GPR-M series (Figure 6.28), for example, has a rated voltage of DC 1000 V, 10 A to 400 A.

6.3.5  Power control Motor/generator control: The motor/ generator control system mainly performs motor control to provide drive as well as regeneration when the motor is acting as a

Figure 6.29  Relays in the battery pack

6  Motors and control systems

Inverter Control Circuit

VB IG

CAN

PWM output

Power Management IC

CAN Transceiver

Chopper Circuit OP-AMP

Isolator

Main MCU

3phase PWM (U/V/W)

Current

IGBT

x6

PreDriver

#3 Motor

A phase B phase Motor position

RD Converter×2

x2 x4

x3

Resolver Sensor

Inverter temp. Motor temp.

OP-AMP

Motor current detection (U/V/W)

Figure 6.30  Motor control system (Source: www.renesas.eu)

generator. The main microprocessor control unit (MCU) controls the inverter via a pre-driver circuit. The sequence in which the inverter (labelled IGBT in Figure 6.30) is switched and at what rate determines the torque and speed of the motor. Key Fact The main microprocessor control unit (MCU) controls the inverter. The insulated-gate bipolar transistor (IGBT) is a three-terminal power semiconductor device primarily used as a fast-acting, high-efficiency electronic switch. It is used to switch electric power in many modern appliances as well as electric vehicles. Inverter: The electronic circuit used to drive a motor is usually called an inverter because it effectively converts DC to AC. An important aspect of this type of motor and its associated control is that it works just as effectively as a generator for regenerative braking. It is controlled by the main MCU in the motor controller. The switches shown in Figure 6.30 will in reality be IGBTs. The IGBTs, in turn, are

Figure 6.31  IGBTs controlled by a pre-driver circuit that produces a signal that will switch the inverter in a suitable sequence. Key Fact An inverter converts DC to AC. The switching actions are shown in Figure 6.32 and the output signal from the inverter when

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6  Motors and control systems Voltage

A

C B

A

B A

Time

Time

C B

C

A

C B

A B

C B

A

C B

Figure 6.32  Representation of the inverter switching operation it is driving the motor is shown, in simplified format, in Figure 6.33.

6.3.6  Pulse-width modulation Pulse-width modulation (PWM) is the process used to control the switching components (IGBTs or MOSFETs) and, therefore, to drive the motor. The switching efficiency using this method usually exceeds 90%.

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Figure 6.33  Simplified inverter output signals Definition

C

A

Time

Pulse-width modulation (PWM): A method of reducing the average power delivered by an electrical signal, by chopping it up into parts. The average value of voltage fed to the load is controlled by turning the switch on and off at a fast rate. PWM controls the power switch output power by varying its ON and OFF times. The ratio of ON time to the switching period time is the duty cycle. Figure 6.34 shows how the duty cycle is varied (blue trace) to produce a sinewave or effectively and AC output. The higher the duty cycle, the higher the power semiconductor switch output power. Figure 6.34 shows just one output. In an EV inverter, this is carried out three times, 120 degrees apart, so as to produce a three-phase output as shown in Figure 6.35. In this image, the output voltage is being varied. This is an actual waveform captured using a PicoScope with an amp clamp on phases U, V and W, which are connected from the inverter to the motor.

6.3.7  Sensors In order to carry out motor/generator switching accurately, the power/control electronics need to

6  Motors and control systems Primary winding Iron core Secondary winding 1

Secondary winding 2

Coils

Sender wheel

Figure 6.34  Inverter switching pattern used to generate three-phase AC from a DC supply know the condition and exact speed and position of the motor. The speed and position information is supplied by one or more sensors mounted on the casing in conjunction with a reluctor ring. Key Fact Power/control electronics need to know the condition and exact speed and position of the motor. The system shown in Figure 6.36 uses 30 sensor coils and an eight-lobe reluctor ring. The output signal changes as a lobe

Figure 6.36  An inductive resolver provides speed and position information approaches the coils, and this is recognised by the control unit. The coils are connected in series and consist of a primary and two secondary windings around an iron core. The separate windings produce different signals (Figure 6.37) because as the reluctor moves, it causes the signal in each secondary winding to be amplified. The position of the rotor can, therefore, be determined with high accuracy using the amplitudes of the signals. The frequency of the signal gives the rotational speed. A drive motor temperature sensor is usually used, and it also sends signals to the electric

Figure 6.35  Current/time graphs showing one complete cycle for each of the three phases

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6  Motors and control systems

Excitation voltage

Secondary winding 1

Secondary winding 2 90

0

180

270

360

Figure 6.37  Sensor signal

PFC* Circuit

Primary-Side Switching Circuit

Transformer Secondary-Side Switching Circuit

AC Volt.

Motor Inverter

Shunt Regulator

PWM

PWM

High-Voltage Detection Circuit

PreDriver

Current Transformer

HEV/EV Secondary Battery

Isolator

Current Detection

PreDriver

CAN

Main MCU

Thermistor CAN Transceiver

Current Detection

* PFC: Power Factor Correction

Figure 6.38  Battery charger circuit and control (Source: www.renesas.eu) drive control unit. Typically, the power of the drive motor is restricted at temperatures above about 150 °C, and, in some cases above 180 °C, it may even prevent the drive from being used to protect it against overheating. The sender is normally a negative temperature coefficient (NTC) thermistor.

6.3.8  Battery Battery charger: A charger and DC–DC step-up system controls the AC input from a household power supply and boosts the voltage, using a DC–DC converter, to whatever is required by the battery. The MCU performs

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power factor correction and control of the DC– DC step-up circuit (Figure 6.38). Key Fact Power factor correction (PFC) is an energy-saving technology that is used to improve the operating efficiency of electrical power systems. Battery control: A battery control system is used for managing remaining battery voltage and control of battery charging. Voltages of individual cells are monitored and the balance

6  Motors and control systems

Isolator

LiBCM IC*

LiBCM IC*

HEV/EV Secondary Battery

CAN 4~12cell CAN Transceiver

Battery Management MCU

CAN Transceiver

CAN Transceiver

Cell Monitor MCU Isolator

LiBCM IC*

* LiBCM IC: Li-ion Battery Cell Management IC

Figure 6.39  Battery control system (Source: www.renesas.eu)

controlled by a battery cell monitor MCU and lithium-ion battery cell monitor integrated circuits (Figure 6.39).

6.3.9  Battery management systems In electric vehicles (EVs), the battery pack requires continuous monitoring to ensure optimal performance and prevent any potential failures. This monitoring is achieved through a battery management system (BMS), which is an electronic system responsible for managing the charging and discharging of the battery cells. The primary function of the BMS is to protect the battery by monitoring various parameters such as temperature and voltage signals from the individual cell modules as well as packlevel current signals. It constantly checks these signals to ensure that the battery operates within its safe operating limits. If any parameter exceeds the predefined thresholds, the BMS takes appropriate actions to mitigate potential risks. The BMS also facilitates the balance or control of the module environment. This involves

managing the state of charge of individual cells within the battery pack as well as ensuring that each cell operates uniformly. By balancing the cells, the BMS helps optimise the overall performance and longevity of the battery pack. To achieve its functions, the BMS requires accurate and reliable operation. It needs to be compact and lightweight, minimising the additional bulk it adds to the battery pack. The BMS is typically connected to a battery management controller (BMC), which receives and processes the monitored signals. The processed signals are then transmitted to the cell management controllers (CMC), which are responsible for balancing the cells and enabling controlled power flow, especially during charging. Connectivity is crucial for transferring signals between the various components of the BMS. This allows for real-time monitoring, analysis and control of the battery pack, ensuring its safe and efficient operation.

6.3.10  Cell balancing High-quality lithium-ion cells have a very uniform capacity and low self-discharge rate when they are new. However, balancing

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6  Motors and control systems the heavy loads during acceleration, which are often followed by fast charging from regenerative braking, it is essential to keep the cells balanced to extend battery life. Passive balancing is a method used to equalise the state of charge (SOC) among the cells in a battery pack. It typically operates at fixed points, either “top balanced”, where all cells reach 100% SOC simultaneously, or bottom balanced, where all cells reach the minimum SOC at the same time.

Figure 6.40  Principle of cell balancing is advantageous because the performance of individual cells can decrease at a slightly different rate. If just one cell in a series connection loses capacity or develops increased self-discharge, the whole string is affected. Passive balancing uses a resistor that can be connected across a cell to divert some of the charge current. This is usually done when the cells are in the range of 70–80% charged. Active balancing takes any extra charge from higher voltage cells during discharge to those with a lower voltage. Key Fact Passive balancing uses a resistor that can be connected across a cell to divert some of the charge current.

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Active balancing is the method used by manufacturers for many EV batteries. It is more complex than passive balancing as it requires DC–DC converters but is more beneficial overall. The corrections to charging current are in the mA range. Because of

In passive balancing, the goal is to transfer energy from cells with a higher state of charge to cells with a lower state of charge. This is accomplished by either bleeding energy from cells with higher SOC, such as through a controlled short circuit using a resistor or transistor, or by shunting energy through a parallel path during the charging cycle. By diverting some of the current away from cells that are already charged, passive balancing ensures that less of the charging current is consumed by those cells. However, passive balancing is inherently inefficient as it results in energy loss in the form of heat. The wasted energy is dissipated as heat in the balancing process, which can be a limitation for rapid balancing. The buildup of waste heat can potentially affect the rate at which balancing can occur. It’s important to note that passive balancing can only take place during steady charging of the battery. It relies on the charging process to redirect current flow and equalise the SOC of the cells. Overall, while passive balancing helps in achieving a more balanced SOC among battery cells, it has limitations in terms of energy efficiency and the speed at which it can balance the cells. Active balancing methods, such as using active electronic circuits, offer more efficient and precise balancing, but they typically require additional components and control algorithms. Active balancing is an alternative method used to redistribute excess energy from cells with

6  Motors and control systems

Figure 6.41  Passive balancing

larger capacity to cells with lower capacity within a battery pack. Unlike passive balancing, active balancing actively transfers energy between cells to achieve a more balanced state of charge (SOC) and make better use of the cells’ capacity. In active balancing, excess energy from cells with a higher SOC can be transferred to cells with a lower SOC through different techniques. One method involves switching a reservoir capacitor in-circuit with the cell, allowing it to absorb excess energy. The capacitor is then disconnected and reconnected to a cell with lower SOC, transferring the stored energy to balance the cells. Another approach is to use a DC-to-DC converter connected across the entire battery pack, which can redistribute energy between cells with different SOC levels. Although some energy is still wasted as heat in active balancing, it is typically less wasteful compared to passive balancing. Active

balancing offers more efficient utilisation of the cells’ capacity by taking advantage of the cells with higher capacity. It’s worth noting that active balancing can occur during both charging and discharging of the battery. This flexibility allows for continuous balancing and maintenance of cell SOC levels. However, active balancing does come with additional costs and complexities. The implementation of active balancing requires additional components such as capacitors, switches or DC-to-DC converters. It also requires control algorithms and circuitry to manage the balancing process effectively. These added complexities and costs may not always be justified depending on the specific application or the characteristics of the battery pack. In summary, active balancing provides more efficient redistribution of energy between cells, leveraging the capacity of more capacious

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6  Motors and control systems

Figure 6.42  Active balancing

Figure 6.43  Cell voltages scanned from a vehicle (good values in this example) cells. It can occur during both charging and discharging. However, the decision to use active balancing should consider the cost, complexity and overall benefits specific to the application at hand.

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6.3.11  Component cooling To protect the sensitive components from high temperatures, the correct temperature is often maintained using coolant. The coolant

6  Motors and control systems

Figure 6.44  Cooling circuit (Source: Volkswagen) temperature can be as high as 65 °C and is electronically monitored and regulated by the motor control unit. The following components are cooled using coolant:

X charging unit X power and control electronics Figure 6.44 shows a cooling circuit from a Volkswagen car. It is typical of many.

X three-phase current drive

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CHAPTER

7

Charging 7.1 Charging, standards and infrastructure 7.1.1  Infrastructure As of 1 July 2023, there were 44,020 public electric vehicle charging devices installed in the UK, within which X 8,461 were rated ‘rapid’ devices or above, this represents 19% of all charging devices X 24,918 were rated ‘fast’ chargers, this represents 56% of all charging devices X 21,294 were designated as ‘destination’ chargers, this represents 47% of all charging devices X 14,848 were designated as ‘on street’ chargers, this represents 34% of all charging devices1

X rapid-charging devices represent 25 kW to 100 kW X ultra-rapid-charging devices represent 100 kW+ Most electric cars will be charged at home, but as noted, national infrastructures are developing. There are, however, competing organisations and commercial companies, so it is necessary to register with a few different organisations to access their charging points. Some are pay-inadvance, some are pay-as-you-go and others require a monthly subscription. Many apps and websites are available for locating charge points. One of the best I have found is www.zap-map. com. Many businesses now also provide charging stations for staff and visitors.

Rapid charging or above devices are those whose fastest connector is rated at 25 kW and above and includes charge points classified as either rapid or ultra-rapid

Although rechargeable electric vehicles and equipment can be recharged from a domestic wall socket, a charging station has additional current or connection-sensing mechanisms to disconnect the power when the EV is not charging. There are two main types of safety sensor:

X slow-charging devices represent 3 kW to 6 kW X fast-charging devices represent 7 kW to 22 kW

1. Current sensors monitor the power consumed and only maintain the connection if the demand is within a predetermined range. DOI: 10.1201/9781003431732-7

7 Charging 2. Additional sensor wires provide a feedback signal that requires special power plug fittings. The majority of public charge points are lockable, meaning passers-by cannot unplug the cable. Some charge points can send a text message to the car owner if the vehicle is unexpectedly unplugged or tell you when the vehicle is fully charged. Safety First Current sensors monitor the power consumed and maintain the charging connection if the demand is within a predetermined range.

Domestic charge points: It is strongly recommended that home charging sockets and wiring are installed and approved by a qualified electrician. A home charge point with its own dedicated circuit is the best way of charging an EV safely. This will ensure the circuit can manage the electricity demand from the vehicle and that the circuit is activated only when the charger communicates with the vehicle, known as the ‘handshake’. For rapid charging, special equipment and an upgraded electrical supply would be required and is, therefore, unlikely to be installed at home, where most consumers will charge overnight. Key Fact

It is safe to charge in wet weather. When you plug in the charge lead, the connection to the supply is not made until the plug is completely in position. Circuit breaker devices are also used for additional safety. Clearly some common sense is necessary, but EV charging is very safe.

Most consumers will charge overnight, but charging from solar panels will also become popular.

Key Fact When you plug in the charge lead, the connection to the supply is not made until the plug is completely in position.

Figure 7.1  Charging point on the roadside (Source: Rod Allday)

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Figure 7.2  Charging point (Source: Richard Webb, www.geograph.ie)

7 Charging take about 10 hours to charge fully and can be ‘opportunity charged’ whenever possible to keep the battery topped up. But it is important to note that this varies a lot depending on the vehicle and the charger. Key Fact Charge time for an EV depends on the type of vehicle, temperature, size of the battery, how discharged the battery is and the type of charge point used. Figure 7.3  Charging at home Pure EVs capable of using rapid charge points could be fully charged in around 30 minutes and can be topped up in around 20 minutes, depending on the type of charge point and available power.

Figure 7.4  Domestic charging point

7.1.2  Standardisation So that electric vehicles can be charged everywhere with no connection problems, it was necessary to standardise charging cables, sockets and methods. The IEC publishes the standards that are valid worldwide, in which the technical requirements have been defined. Table 7.1 lists some of the most important standards associated with the charging of EVs.

7.1.3  Charging time and cost How long it takes to charge an EV depends on the type of vehicle, how discharged the battery is and the type of charge point used. Typically, pure electric cars using standard charging will

The cost of charging an EV depends on the size of the battery and how much charge is left in the battery before charging. If you charge overnight, you may be able to take advantage of cheaper electricity rates when there is surplus energy. The cost of charging from public points will vary; many will offer free electricity in the short term. It is also possible to register with supply companies who concentrate on energy from renewable sources. Here is a simple way to calculate cost of recharging: X electricity is paid for in units (1 unit is 1 kWh) X charging is about 85% efficient (but often better) To charge a large 100 kWh battery from 20% to 80% requires 60 kWh Divide this by the efficiency (85%) and the answer is just over 70 kWh – multiply this by the cost per unit of electricity (let’s say 30 p, but this will vary a lot) and it would cost about £21. I currently buy electricity (overnight rate) at 7.5 p per unit so a recharge like this costs just over £5. Compare this with an ICE top up . . .

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Table 7.1  Charging standards IEC 62196–1

IEC 62196–2

IEC 62196–3

IEC 61851–1

IEC 61851–21–1

IEC 61851–21–2

HD 60364–7–722

Plugs, socket outlets, vehicle connectors and vehicle inlets.

Dimensional compatibility and interchangeability requirements for AC pin and contact tube accessories. The permissible plug and socket types are described

Dimensional compatibility and interchangeability requirements for dedicated DC and combined AC/DC pin and contact tube vehicle couplers

Electric vehicle conductive charging system.

Electric vehicle conductive charging systems.

Different variants of the connection configuration, as well as the basic communication with the vehicle, are defined in this standard

Electric vehicle on-board charger EMC requirements for conductive connection to an AC/DC supply

Electric vehicle conductive charging systems EMC requirements for off-board electric vehicle charging systems

Low-voltage electrical installations. Requirements for special installations supply of electric vehicles

Conductive charging of electric vehicles

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Figure 7.5  Charging forecourt (Source: Gridserve)

7.1.4  Charging methods, modes and plugs There are a number of different methods and modes of EV charging explained in this section, but, at a simple level, there are two distinct types of charging: X alternating current (AC) X direct current (DC) Power is supplied from the grid as AC, but an EV battery is always charged using DC. The current, therefore, needs to be converted from AC to DC, and where this takes place depends on the type of charge point. This is summarised in Figure 7.6. AC charging: Alternating current charging has now established itself as a standard charging method. It is possible in the private sector, as well as at charging stations in the semi-public and public sector, with relatively low investments. Consequently, this charging method also has a long-term future. Standard charging occurs via an

alternating current connection and is the most common and most flexible charging method. In charging Modes 1 and 2, charging is possible on household sockets or on CEE sockets. On the household socket, charging can take up to several hours due to the power limited through the socket, depending on rechargeable battery capacity, fill level and charging current. Key Fact Alternating current charging has now established itself as the standard charging method. In charging Mode 3, a vehicle can be charged at a charging station where power of up to 43.5 kW is possible with a significantly reduced charging time. Particularly in the private sector, the usable power is limited by the fuse protection of the building connection. Charging powers to maximum 22 kW at 400 V AC are

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Figure 7.6  AC and DC charging modes

usually the high power limit for home charging stations. The charging device is permanently installed in the vehicle. Its capacity is adjusted to the vehicle battery. Compared with other charging methods, the investment costs for AC charging are moderate. DC charging: With direct-current charging, there is a distinction between X DC low charging: up to 38 kW with type 2 plugs X DC high charging: up to 170 kW The charging device is part of the charging station, so DC-charging stations are significantly more expensive as compared with AC charging stations. The prerequisite for DC charging is an appropriate network of charging stations, which due to the high power require high infrastructure investments. Fast charging with high currents requires appropriately dimensioned line cross-sections that make connecting the vehicles to the charging station more cumbersome. Standardisation of the DC-charging connection has not yet been concluded, and market availability is still uncertain. In practice, vehicles with a

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DC-charging connection have an additional connection for standard charging so that the vehicle can also be charged at home. Key Fact DC-charging stations are significantly more expensive compared with AC-charging stations. Inductive charging: Charging occurs without contacts via inductive loops. The technical complexity and, thus, the costs are considerable for the charging station as well as the vehicle. This system is not yet ready for the market or for large-scale production. Definition Inductive charging: no physical connection is made; instead, transformer action or mutual induction is used. Battery replacement: The vehicle’s rechargeable battery is replaced with a fully charged battery at the change station. In this

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Figure 7.7  Inductive charging

Figure 7.8  Charging modes and a summary of each

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7 Charging case, you can continue driving after a few minutes. The prerequisite for this concept would be that vehicle manufacturers would have to install standardised rechargeable batteries at standardised positions in the vehicle. However, such standardisation would hardly be possible due to the different vehicle types and uses. The charge stations would have to keep battery types for the different vehicles on hand, which in practice would be equally difficult. Consequently, battery replacement could only be implemented today in closed fleets. Four different charging modes have been defined for safe charging of electric vehicles in line with demand. These charging modes differ relative to the power source used (protective contact, CEE, AC- or DC-charging socket), and they differ relative to the maximum charging power and the communication possibilities. Safety First Four different charging modes have been defined for safe charging of electric vehicles. Mode 1: This mode charges from a socket to max 16 A, three-phase without communication with the vehicle. The charging device is integrated in the vehicle. Connection to the energy network occurs via an off-the-shelf, standardised plug and socket that must be fused via a residual current protective device. This method is not recommended because Mode 2 offers greater safety thanks to communication with the vehicle. Mode 2: This mode charges from a socket to max 32 A, three-phase with a control function and protective function integrated in the cable or the wall-side plug. The charging device is installed in the vehicle. Connection to the energy network occurs via an offthe-shelf, standardised plug and socket. For Mode 2, the standard prescribes a mobile device to increase the level of protection.

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Moreover, for the power setting and to satisfy the safety requirements, a communication device is required with the vehicle. These two components are combined in the in-cable control box (ICCB). Mode 3: This mode is for charging at AC-charging stations. The charging device is a fixed component of the charging station and includes protection. In the charging station, PWM communication, residual current device (RCD), overcurrent protection, shutdown and a specific charging socket are prescribed. In Mode 3, the vehicle can be charged threephase with up to 63 A, so a charging power of up to 43.5 kW is possible. Depending on rechargeable battery capacity and charge status, charges in less than one hour are possible. Mode 4: This mode is for charging at DC-charging stations. The charging device is a component of the charging station and includes protection. In Mode 4, the vehicle can be charged with two plug-and-socket systems, both of which are based on the type 2 plug geometry. The ‘combined charging system’ has two additional DC contacts to 200 A and up to 170 kW charging power. The other option is a plug and socket with lower capacity for a charge to 80 A and up to 38 kW in type 2 design. Standards continue to be reviewed and changed to improve safety and ease of use as well as compatibility.

Figure 7.9  In-cable control box (ICCB)

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Figure 7.10  Current and future charging methods

Figure 7.11  AC or DC CCS2 charging socket (Source: TE) Figure 7.10 compares different charging methods (standard and proprietary). Safety First Voltage is only switched on when the system has detected that the plugs on the vehicle side and infrastructure side are completely plugged in, that the plugs are locked and that the protective conductor connection is correct.

7.1.5  Communication Basic communication: Safety check and charging current limitation is determined. Even before the charging process starts, in charging Modes 2, 3 and 4, PWM communication with the vehicle occurs via a connection known as the control pilot (CP) line. Several parameters are communicated and coordinated. The charging will only begin if all security queries clearly correspond to the specifications and the maximum permissible charging current

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7 Charging Table 7.2 Charging plugs Type of plug

Image

Type 1 is a single-phase charging plug developed in Japan exclusively for the vehicle side-charging connection. The maximum charging power is 7.4 kW at 230 V AC. Type 1 offers insufficient possibilities for the three-phase European networks. This plug is defined by SAE J1772 standard and is also known as a J plug. It is a North American standard.

Figure 7.12 Type 1 plug (J plug in the USA) Type 2 The IEC 62196 Type 2 connector (often referred to as Mennekes) is used mainly within Europe, as it was declared standard by the EU. The connector is circular in shape, with a flattened top edge; the original design specification carried an output electric power of 3–50 kW using single-phase (230 V) or three-phase (400 V) alternating current (AC), with a typical maximum of 32 A 7.2 kW using single-phase AC and 22 kW with three-phase AC. The plugs have openings on the sides that allow both the car and the charger to lock the plug automatically to prevent unwanted interruption of charging or theft of the cable.

Figure 7.13 Type 2 plug

CHAdeMO stands for CHArge de MOde and was developed in 2010. The latest CHAdeMO Protocol (3.0) allows for up to 900 kW of charging (600 A x 1.5 kV) through the CHAdeMO/CEC collaboration. This plug has mostly been replaced by CCS in Europe.

Figure 7.14 CHAdeMO plug (Source: D-Kuru) Combined charging system (CCS) covers charging electric vehicles using the combo 1 and combo 2 connectors at up to 80 or 350 kW. These two connectors are extensions of the type 1 and type 2 connectors, with two additional direct current (DC) contacts to allow high-power DC fast charging. CCS allows AC charging using the type 1 and type 2 connector depending on the geographical region. Since 2014, the EU has required the provision of type 2 or combo 2 within the European electric vehicle network. Tesla’s current plug in Europe is based on the type 2 Mennekes connector, which is basically identical to the top half of the CCS combo 2 plug. The current Supercharger network is being updated, while it appears that the existing type 2 plugs will fit in the top half of the CCS type 2, apparently this may not charge the Tesla.

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Figure 7.15 CCS combo plug type 1

Figure 7.16 CCS combo plug type 2 socket (Source: Tesla)

7 Charging has been communicated. These test steps are always executed: Definition PWM: pulse-width modulation. 1. The charging station locks the infrastructure side-charging coupler. 2. The vehicle locks the charging coupler and requests start of charging. 3. The charging station (in Mode 2, the control unit in the charging cable) checks the connection of the protective conductor to the vehicle and communicates the available charging current. 4. The vehicle sets the charger accordingly. If all other prerequisites are met, the charging station switches the charging socket on. For the duration of the charging process, the protective conductor is monitored via the PWM connection and the vehicle has the possibility of having the voltage supply switched off by the charging station. Charging is ended, and the plugs and sockets are unlocked via a stop device (in the vehicle). Limitation of the charging current: The vehicle’s charging device determines the charging process. To prevent the vehicle charging device from overloading the capacity of the charging station or of the charging cable, the power data of the systems is identified and adjusted to match. The CP box reads the power data of the cable from the cable. Before the charging process is started, the box communicates the power data to the vehicle via PWM signal, the vehicle’s charging device is adjusted accordingly and the charging process can begin, without the possibility of an overload situation occurring. Key Fact The vehicle’s charging device determines the charging process.

Figure 7.17  Type 2 AC charging plug and its pinout The weakest link in the charging chain determines the maximum charging current: The charging current in the charger is limited depending on the power of the charging station and the resistance coding in the plug of the charging cable. Key Fact The weakest link in the charging chain determines the maximum charging current.

7.1.6  Fast charging Before discussing fast charging further, we must repeat the general charging advice as summarised in Figure 7.18: Store cold, use hot, charge slow and store half-full! However, fast charging from time to time is perfectly fine (but check the manufacturer’s recommendations as this may affect the battery warranty). Figure 7.19 shows typical charge times as related to the power available from the charge and assumes the vehicle is able to accept the full amount. It is okay to use a DC fast charger when you are on a trip and need to recharge your EV in a half hour. But manufacturers suggest

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Figure 7.18  Prolonging the life of a battery (in your phone and car)

Figure 7.19  Charge times

it is best not to use Level 3 charging on a daily basis. Battery degradation is caused by loss of active lithium and increased internal resistance. The factors involved in this are X temperature X depth of discharge

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X charging rates X battery cell design X age Fast charging (excessively) can cause plating as shown in Figure 7.20. Again, we would stress fast charging is fine when needed – just limit it where possible!

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Figure 7.20  Dangers of fast charging (Source: About: Energy)

7.1.7  Vehicle-to-grid Vehicle-to-grid (V2G) is a system that uses bidirectional power from the car to the grid as well as the normal charging routine of grid to car. If this system is employed, the car battery can be used as a power backup for the home or business. If the car is primarily charged from renewable sources such as PV panels or wind generation, then returning this to the grid is not only ecologically beneficial but also an ideal way of stabilising fluctuations of demand in the grid. The potential problem is managing inrush currents if lots of vehicles fast charge at the same time. This notion is still a little way into the future at the time of writing (2023), but the concept of the ‘smart grid’ using techniques such as this is not far off. However, one key stumbling block to the V2G technology is the battery warranty. Most battery manufacturers guarantee their batteries for a set time (several years) but have a proviso that there is a limit on how much it is used because use is increased with V2G. This is often described as ‘coulombs in and coulombs out’. The coulomb (C) is the SI unit of electric charge. It is the charge (Q) transported by a constant current of one ampere in one second.

Definition The coulomb (C) is the SI unit of electric charge. It is the charge (Q) transported by a constant current of one ampere in one second.

7.1.8  Charging case study The lithium-ion battery system of the Audi e-tron GT quattro and the RS e-tron GT can store 84 kWh of energy net (93 kWh gross). It integrates 33 cell modules, each of which comprises 12 pouch cells with flexible outer skin. Each module is fitted with its own computer that monitors the temperature and voltage. The unusually high system voltage of approximately 800 V enables a powerful continuous output and shortens the charging duration; in addition, it reduces the weight of and space required by the wiring. This battery system is located beneath the passenger compartment, at the lowest point of the car. This, in combination with the electric motors, provides a low centre of gravity appropriate for a sports car and a weight distribution between the front and rear axles that is very close to the ideal value of 50:50. Thirty modules form the lower level

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Figure 7.21  Audi e-tron charging performance (Source: Audi Media)

of the battery, which features a wide recess in the rear section. It creates space for the rear passengers’ feet, which allows them to sit in a low position and also enables the flat vehicle silhouette. The upper floor contains three further modules situated below the rear seats. The connections, fuses and the main control unit are located under the console of the centre tunnel. The bottom of the battery is protected by an aluminium plate.

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circulates in its own low-temperature circuit. The temperature is transferred between the cooling plates and the cell space via a heatconducting paste. The battery’s feel-good temperature is between 30 ºC and 35 ºC, and its operating range extends from −30 ºC to 50 ºC.

The inner structure of the battery that houses the module, the frame surrounding it and the upper cover plate are made of aluminium. As in the body, die-cast sections, extruded sections and aluminium sheets are used here. The battery system contributes significantly to the rigidity of the body to which it is attached via 28 screws. At the same time, it improves passive safety in the event of a front and side impact.

Four separate coolant circuits, each at its own temperature level, regulate the temperature in the high-voltage components and the interior precisely and quickly. They can be interconnected flexibly as required. If the driver demands a high output several times in a row, valves couple the coolant circuit of the battery with the refrigerant circuit of the air-conditioning system – this intensive cooling keeps the performance of the drive at a consistently high level. The e-tron GT quattro and RS e-tron GT can accelerate to full speed from a standstill up to 10 consecutive times.

Beneath the cell space of the battery, there is a compound structure of flat extruded sections through which a glycol/water mixture flows that

The refrigerant circuit also helps with cooling during fast DC charging, which can heat the battery up to 50 ºC. The thermal management

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Figure 7.22  Audi battery and system

is connected to the navigation system. When the driver sets a high power charging (HPC) terminal as the destination, the cooling of the battery is already intensified on the way to the charging station so that it can be charged as quickly as possible. Should the battery still be very cold shortly after the car is started in winter, it is heated for fast charging. The standard equipment of the e-tron GT includes a heat pump that heats the interior with the waste heat of the high-voltage components. It can reduce the loss of range that the electric climate control causes in winter, in particular, significantly. In addition to charging, customers can also manage preentry climate control of the interior via their smartphones using the myAudi app. This is done via a powerful high-voltage heating element and does not depend on the car charging via the power grid. Audi equips the e-tron GT with a deluxe auxiliary air-conditioning system as an option that also incorporates the steering wheel rim (if heatable), the exterior mirrors and the rear window.

The charging flaps of the GT are located behind the front wheels. Both sides feature connections for alternating current (AC), and there is also a connection for direct current (DC) on the right-hand side. The Audi e-tron GT is delivered to its customers with two charging cables as standard: one Mode 3 cable for public AC terminals and the charging system compact for the garage. The e-tron GT can charge with 11 kW AC as standard, which allows it to recharge an empty battery overnight. An optional on-board charger for 22 kW will follow shortly after the market launch. At a direct-current terminal with a voltage of 800 V, for example, in the European motorway network from Ionity, the Audi e-tron GT achieves a peak charging capacity of up to 270 kW. This allows it to recharge energy for up to 100 kilometres (62.1 mi) in just over five minutes and charging from 5% to 80% SoC (state of charge) takes less than 23 minutes under ideal conditions. The driver can restrict the charging target if the rate appears too high.

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7 Charging 7.2  Wireless power transfer 7.2.1  Introduction Range anxiety continues to be an issue to EV acceptance. Wireless power transfer (WPT) is a means to increase the range of an electric vehicle without substantial impact on the weight or cost. WPT is an innovative system for wirelessly charging the batteries in electric vehicles. There are three categories: X stationary WPT: Vehicle is parked; no driver is in the vehicle. X quasi‐dynamic WPT: Vehicle is stopped; driver is in the vehicle. X dynamic WPT: Vehicle is in motion.

without passengers on board). It is important to keep the geometrical alignment of primary and secondary within certain tolerance values in order to ensure a sufficient efficiency rate of the energy transfer. With quasi-dynamic wireless charging, the energy is transferred from the roadside primary coil system of limited length to the secondary coil of a slowly moving, or in stop-and-go mode moving vehicle (with passengers). With dynamic wireless charging, the energy is transferred via a special driving lane equipped with a primary coil system at a high power level to a secondary coil of a vehicle moving with medium to high velocity.

7.2.2  Stationary WPT

Definition WPT: wireless power transfer. There are also three WPT power classes (SAE J2954): X light-duty home: 3.6 kW X light _duty fast charge: 19.2 kW X high-duty: 200–250 kW With stationary charging, the electric energy is transferred to a parked vehicle (typically

In this option, electric vehicles simply park over an induction pad and charging commences automatically. WPT requires no charging poles or associated cabling. It can accommodate differing rates of charge from a single on-board unit, and the rate of charge or required tariff can be set from within the vehicle. It has no visible wires or connections and only requires a charging pad buried in the pavement and a pad integrated onto the vehicle.

Vehicle

Communication link Capacitor, bank and regulator

On board coil Utility interface

Power inverter and controller

Off board coil

Figure 7.23  WPT principle (Source: CuiCAR)

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Energy storage system

Motor

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1

5 6 4 3 2

Figure 7.24  An inductive wireless charging system for statically charging an EV: 1) power supply, 2) transmitter pad, 3) wireless electricity and data transfer, 4) receiver pad, 5) system controller, 6) battery (Source: haloIPT) Key Fact Electric vehicles simply park over an induction pad and charging commences automatically. The system works in a range of adverse environments including extremes of temperature, while submerged in water or covered in ice and snow. It will operate under asphalt or embedded in concrete and is also unaffected by dust or harsh chemicals. WPT systems can be configured to power all roadbased vehicles from small city cars to heavygoods vehicles and buses. The power supply takes electrical power from the mains supply and energises a lumped coil, with a current typically in the range 5–125 A. Definition Power factor: the ratio of the real power flowing to the load to the apparent power in the circuit, expressed as a percentage or a number between 0 and 1. Real power: capacity of the circuit for performing work in a particular time. Apparent power: the product of the current and voltage of the circuit.

Pick-up coils are magnetically coupled to the primary coil. Power transfer is achieved by tuning the pick-up coil to the operating frequency of the primary coil with a series or parallel capacitor. The power transfer is controllable with a switch-mode controller. A block diagram for a single-phase wireless charger is shown as Figure 7.18. The mains supply is rectified with a full bridge rectifier followed by a small DC capacitor. Keeping this capacitor small helps the overall power factor and allows the system to have a fast start-up with a minimal current surge. The inverter consists of an H-bridge to energise the tuned primary pad with current at 20 kHz. The 20 kHz current also has a 100 Hz/120 Hz envelope as a result of the small DC bus capacitor. Power is coupled to the secondary tuned pad. This is then rectified and controlled to a DC output voltage appropriate to the vehicle and its batteries. The conversion from AC to DC and back to AC, in the power supply side, is necessary so the frequency can be changed. Definition Inverter: an electrical device that converts direct current into alternating current.

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Rectifier

Small DC Capacitor

Inverter

Primary Pad

Secondary Pad

Compensation Rectifier/ Controller DC Load

AC 240V Power Supply

Controller

Figure 7.25  IPT (WPT) system components (Source: haloIPT)

The system includes three distinct hardware components: 1. High-frequency generator or power supply 2. Magnetic coupling system or transmitter/ receiver pads 3. Pick-up controller/compensation The high-frequency generator takes a mains voltage input (240 V AC at 50/60 Hz) and produces high-frequency current (>20 kHz). The output current is controlled and the generator may be operated without a load. The efficiency of the generator is high at over 94% at 2 kW. The generator comprises the following X mains filter (to reduce EMI) X rectifier X bridge (MOSFETs) converting DC to high frequency X combined isolating transformer/AC inductor X tuning capacitors (specified for frequency and output current) X control electronics (microcontroller, digital logic, feedback and protection circuits)

Definition EMI: electromagnetic interference. The design and construction of the transmitter and receiver pads gives important improvements over older pad topologies. This results in better coupling, lower weight and a smaller footprint, for a given power transfer and separation. The pads can couple power

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over gaps of up to 400 mm. The coupling circuits are tuned through the addition of compensation capacitors. Safety First All high-voltages are completely isolated, but note that safe working methods are necessary. A pick-up controller takes power from the receiver pad and provides a controlled output to the batteries, typically ranging from 250 V to 400 V DC. The controller is required to provide an output that remains independent of the load and the separation between pads. Without a controller, the voltage would rise as the gap decreased and fall as the load current increased. Key Fact A CAN interface is used for control and feedback. BMW has developed a wireless charging system. The principal benefit of this system is ease of use because drivers don’t need to plug in a charging cable. As soon as the vehicle has been parked in the correct position above the inductive charging station, followed by a simple push of the Stop/Start button, the charging process is initiated. Once the battery is fully charged, the system switches off automatically.

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Figure 7.26  Charging station (Source: BMW Media)

Energy from a main power supply is transferred to a vehicle’s high-voltage battery without any cables. This can be installed in the garage. The BMW system also helps the driver to manoeuvre the car into the correct parking position with the help of a Wi-Fi connection between the charging station and vehicle. An overhead view of the car and its surroundings is displayed in the centre control display. Coloured lines help guide the driver into the correct spot. A graphic icon shows when the correct parking position for inductive charging has been reached. This can deviate from the optimum position by up to 7 cm longitudinally and up to 14 cm laterally. The system consists of an inductive charging station (GroundPad) and a secondary vehicle component (CarPad) fixed to the underside of the vehicle. The contactless transfer of energy between the GroundPad and CarPad is conducted over a distance of around 7.5 cm. The GroundPad generates a magnetic field.

This induces a voltage in the CarPad, which then causes a current flow and charges the high-voltage battery. During charging, ambient electromagnetic radiation is limited to the vehicle undercarriage. The GroundPad is permanently monitored and will be switched off if any foreign matter is detected. Foreign object detection and living object detection are part of the certified induction charging system. It will switch off charging if something is detected within the gap between the vehicle and ground pads. The system has a charging power of 3.7 kW, enabling the high-voltage batteries on board a BMW 530e iPerformance, for example, to be fully charged in around three-and-a-half hours. The system has an efficiency of around 85%.

7.2.3  Dynamic WPT It seems illogical in many ways but the prospect of wirelessly charging an EV as it

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Traffic Lanes ane

WPT L

n

Media RSU

tributio

dc dis

n

ane

WPT L

Traffic Lanes

RSU –

+

Side view Cover plate Windings Top view

Ferrite pieces HF IN V

DC-DC

DC distribution & power command

Figure 7.27  Principle of dynamic wireless charging – RSU is a roadside unit (Source: Oakridge National Lab)

drives along a road is already possible and being trialled in a number of countries. The principle is fundamentally the same as static wireless charging but even more complex. The technology is known as wireless power transfer (WPT). The challenges with this technology are X synchronisation of energising coils (timing of power transfer) X acceptable power levels X vehicle alignment X allowable speed profiles X multiple vehicles on charging lane A number of feasibility studies and trials are ongoing, and it is expected that this system will be available in the near future. Figure 7.27 shows the principle of dynamic WPT. Driver assistance systems may play a role in combination with wireless charging. With stationary wireless charging, a system

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could be developed where the vehicle is parked automatically, and, at the same time, primary and secondary coils are brought into perfect alignment. With quasi-dynamic and dynamic charging, the vehicle speed as well as horizontal and vertical alignment could be automatically adapted by dynamic cruise control and lane assist. This would increase the efficiency rate of the energy transfer because of the need to synchronise energy transfer via the coil systems. Key Fact Driver assistance systems may play a role in combination with wireless charging.

Communication will be essential to exchange standardised control commands in real time between the grid and the vehicle control systems.

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Vehicle 2 I

DSRC

DSRC

CAN

Energy Storage System

DSRC Vehicle 1

Vehicle 1 DSRC

Charging Station

DSRC

Vehicle 3

DSRC

DSRC Vehicle n

Figure 7.28  Communication is essential for dynamic WPT

For safety reasons, vehicles in other lanes and other users of the main coil system in the charging lane need to be monitored in real time. Dedicated short-range communication (IEEE 802.11p) is a likely technology that will be used for low‐latency wireless communication in this context. Finally, powerful electromagnetic fields are used in the active charging zone between

primary and secondary coils. For human safety in this respect, compliance with international standards needs to be achieved.

Note 1 https://www.gov.uk/government/statistics/ electric-vehicle-charging-device-statisticsjuly-2023/electric-vehicle-charging-devicestatistics-july-2023

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CHAPTER

8

Maintenance, repairs and replacement 8.1  Before work commences 8.1.1  Introduction Before carrying out any practical work on an EV, you should be trained or supervised by a qualified person. Refer to Chapter 1 for procedures on safe working and PPE and making the system safe for work. Key aspects of practical work on EVs (and any other vehicles for that matter) are as follows: X observation of health and safety X correct use of PPE X correct use of tools and equipment X following repair procedures X following workplace procedures X referral to manufacturer-specific information Safety First Before carrying out any practical work on an EV, you should be trained or supervised by a qualified person. Note: There are some excellent training courses available across the UK relating to electric vehicles and other subject areas. The IMI offer a range of CPD courses, and you can search here:

X The Institute of the Motor Industry: www.theimi.org.uk/cpd/search I am pleased to recommend the theory and hands-on practical courses run by: X ProMoto: www.pro-moto.co.uk X TechTopics: www.techtopics.co.uk

8.1.2  Technical information There are many sources of technical and other information, but in the case of EVs, it is essential to refer to the manufacturer’s data, safety data sheets and workshop manuals. You should also be aware of the appropriate technique for gathering information from drivers/customers. For example, asking questions politely about when, where or how a problem developed can often start you on the road to the solution. General sources of information include the following: X paper-based, electronic X on vehicle data/warnings X wiring diagrams X repair instructions X bulletins X verbal instruction An example of a manufacturer’s data about component location is shown in Figure 8.1. DOI: 10.1201/9781003431732-8

8  Maintenance, repairs and replacement Information from rescue data sheets is also very useful. An example from Audi is shown as Figure 8.2.

4 5 6

3 2

7

1

10

9

8

Figure 8.1  Components on a Volkswagen Golf GTE: 1) three-phase current drive (electric drive motor, drive motor temperature sensor, 2) high-voltage battery charging socket, 3) electrical air conditioner compressor, 4) combustion engine, 5) battery regulation control unit, 6) high-voltage battery, 7) highvoltage cables, 8) high-voltage heater (PTC), 9) power and control electronics for electric drive (control unit for electric drive, intermediate circuit capacitor, voltage converter, DC/AC converter for drive motor), 10) charging unit 1 for high-voltage battery (Source: Volkswagen Group)

Figure 8.3  Sample from the Pro-Moto app

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Figure 8.2  Sample page from the Audi rescue data sheets (Source: Audi)

8  Maintenance, repairs and replacement A range of apps are now also available that include useful information, but remember, nothing beats the manufacturer, so this is always the data you should use where possible.

8.1.3  De-energising Different manufacturers have different ways to de-energise the high-voltage system (you must refer to specific data for this operation). Here I have presented a typical but generic example of a de-energisation process:

Figure 8.4  Maintenance connector (green) and warning label on a Golf GTE

Safety First Always refer to the manufacturer’s data before de-energising the high-voltage system.

In some cases, a technician qualified in highvoltage may carry out the de-energisation process for others to then do specific work.

Here is a typical routine:  1. Use appropriate PPE at all times.  2. Place high-voltage warning signs and a fence around the vehicle with posts and barrier tape or similar.  3. Disconnect the charging plug.  4. Switch ignition ON, connect scanner and check for faults.  5. Connect scanner and check that highvoltage readings are normal.  6. Switch OFF the ignition.  7. Remove the service connector.  8. Lock service connector to prevent accidental re-connection.  9. Switch ON the ignition. 10. Check dashboard warnings. 11. Connect scanner and check that highvoltage readings are ZERO 12. Switch OFF the ignition and remove the key to a safe place (at a distance if a remote key) 13. Check correct operation of a multimeter on a low-voltage source 14. Check for ZERO voltage at the inverter using a Cat III (minimum) multimeter and leads.

Figure 8.5  Warning signs used when work is being carried out on a vehicle after de-energisation

8.2  During work 8.2.1  Maintenance intervals Maintenance intervals on electric and hybrid vehicles vary between models and manufacturers. Always refer to the manufacturer’s data. Using an eGolf as an example, inspections depend on the length of time and the mileage. The first inspection takes place after 30,000 km or 24 months, followed by every 12 months or 30,000 km after that, depending on which comes first. The brake fluid inspection is recommended after three years, followed by every two years.

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8  Maintenance, repairs and replacement 8.2.2  Repairs affecting other vehicle systems If care is not taken, work on any one system can affect another. For example, removing and replacing something as simple as an oil filter can affect other systems if you disconnect the oil pressure switch accidently or break it by slipping with a strap wrench. For this reason – and, of course, it is even more important when dealing with a highenergy system – you should always consider connections to other systems. A good example would be if disconnecting a 12 V battery on an HEV, the system could still be powered by the high-voltage battery and DC–DC converter. Manufacturer’s information is, therefore, essential. Electromagnetic radiation (or interference) can affect delicate electronics. Most engine control units are shielded in some way, but the very high–strength magnets in the rotor of some EV motors could cause damage. From a different perspective, an interesting news article recently noted how lots of drivers in a specific car park could not unlock their vehicles remotely.1 This is still under investigation, but it sounds like an electromagnetic radiation (EMR) issue to me – power lines nearby perhaps!

Figure 8.6  Domestic mains and charge point cables X the current draw capability of the vehicle X potential for short circuits and the subsequent vehicle component damage In addition, you must be able to identify components and the connection methods used. High-voltage components and highvoltage cables should undergo a visual check for damage and correct routing as well as security. Pay attention to the following during the visual check:

Definition EMR: electromagnetic radiation.

8.2.3  Inspect high-voltage components During any service or repair operation, it is important to inspect high-voltage components. This includes the charging cables shown as Figure 8.6.

8.2.4  Cables Two key aspects when inspecting high-voltage components to be aware of are

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Figure 8.7  Warning and information supplied as part of the charging cables X any external damage to the high-voltage components X defective or damaged insulation of highvoltage cables X any unusual deformations of high-voltage cables

8  Maintenance, repairs and replacement for electric drive, high-voltage cables for battery and air conditioning compressor, highvoltage cable for electric drive as well as highvoltage charging socket in radiator grille or in tank cap as appropriate. Underbody: Check high-voltage battery as well as high-voltage cables for battery.

Figure 8.8  High-voltage cables

8.2.5  Battery Check high-voltage batteries for X cracks in upper part of battery housing or battery tray X deformation of upper part of battery housing or battery tray X colour changes due to temperature and tarnishing of housing X escaping electrolyte X damage to high-voltage contacts X fitted and legible information stickers X fitted potential equalisation line X corrosion damage

Figure 8.10  Battery pack bonding strap on a Nissan LEAF

8.3  Remove and replace 8.3.1  High-voltage components The main high-voltage (also described as highenergy) components are generally classified as X cables (orange!) X drive motor/generator

Figure 8.9  Battery pack

8.2.6  Other components Engine compartment area: Check the condition of the power and control electronics

Figure 8.11  The AC compressor on this car is driven by a high-voltage motor but still deep down on the side of the engine. You can just make out the orange supply cable here!

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8  Maintenance, repairs and replacement X Wear eye protection. X Risk of severe or fatal injury due to electric shock is present. All high-voltage remove-and-replace jobs will start with the de-energising process and, after completion, the re-energising process.

Figure 8.12  Toyota Prius engine bay

Manufacturer’s information is essential for any remove-and-replace job that involves high-voltage. Generic instructions for any component would be something like the following but more detailed: 1. De-energise the system. 2. Drain coolant if appropriate (many highvoltage components require cooling). 3. Remove any covers or cowling. 4. Remove high-voltage cable connections (for safety reasons, some connectors are double locked, Figure 8.14 shows an example). 1

3

Figure 8.13  Volkwagen Golf GTE engine bay X battery management unit X power and control unit (includes inverter) X charging unit X power steering motor X electric heater X air-conditioning pump

2

A

4

B

1

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General safety points to note with this type of work (see also Chapter 2, “Safe Working, Tools and Hazard Management”): X Poisonous dust and fluids pose a health hazard. X Never work on high-voltage batteries that have short-circuited. X Danger of burns from hot high-voltage battery is a possibility. X Hands may sustain burns. X Wear protective gloves. X Cooling system is under pressure when the engine is hot. X Risk of scalding to skin and body parts is present.

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C 5 2

D Figure 8.14  Locking connectors: Pull out lock 3 in direction A; Push mechanism 4 in direction B and pull off connector 1 until it is against the second lock; Push mechanism 5 in direction D and the connector can now be removed completely

8  Maintenance, repairs and replacement 5. Remove securing bolts/nuts as necessary. 6. Remove the main component.

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Safety First Manufacturer’s information is essential for any remove-and-replace job that involves high-voltage.

4 6

3

8.3.2  Battery pack For most battery-removal jobs, special tools and workshop equipment may be necessary, for example: X hose clamps X scissor-type lift platform X drip tray X protective cap for power plug Typical removal process:  1. De-energise high-voltage system.  2. Remove underbody covers.  3. Remove silencer.  4. Remove heat shield for high-voltage battery.  5. Open filler cap on coolant expansion tank.  6. Set drip tray underneath.  7. Remove potential equalisation line.  8. Disconnect high-voltage cables.  9. Fit protective cap onto high-voltage connection. 10. Clamp off coolant hoses with hose clamps. 11. Lift retaining clips, remove coolant hoses from high-voltage battery and drain coolant. 12. Prepare scissor-type lift assembly platform with supports. 13. Raise lift assembly platform to support the high-voltage battery. 14. Remove mounting bolts. 15. Lower high-voltage battery using lift assembly platform. Installation is carried out in the reverse order; note the following: X Tighten all bolts to specified torque. X Before connecting high-voltage cable, pull protective cap off high-voltage connection. X Refill coolant. X Re-energise high-voltage system.

7 2 1

8

10

9

Figure 8.15  Battery pack: 1) bolt, 2) nut, 3) potential equalisation line, 4) coolant hoses, 5) high-voltage battery, 6) gasket, 7) battery regulation control unit, 8) bolt, 9) captive nut, 10) bolt (Source: Volkswagen Group)

8.3.3  Low-voltage components As well as high-voltage, a large part of our work on EVs will be working on the lowvoltage systems. Sometimes these are described as ‘low-energy’ to distinguish them from the ‘high-energy’ components such as the drive motor – but do remember that components such as a starter motor are low-voltage but not low energy! Low-voltage systems will include X control units/fuse boxes X low-energy components associated with interior heating X wiring harness/cabling X battery X starter motor X alternator X switches X lighting X low-energy components associated with air conditioning X alarm/immobiliser X central locking

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8  Maintenance, repairs and replacement 8.4.2  Results, records and recommendations

Figure 8.16  Standard 12 V starter motor (Source: Bosch Media) X electric windows/wipers/washers X central locking For full details on these systems, please refer to one of our other books: Automobile Electrical and Electronic Systems (www. tomdenton.org).

8.4  Completion of work 8.4.1  Re-energising Different manufacturers have different ways to re-energise the high-voltage system (you must refer to specific data for this operation). Here I have presented a typical generic example of a re-energisation process:

This alliterative section is often overlooked, but it is very important to make a final check of any test results, keep a record of them and then, when appropriate, make recommendations to the customer. To interpret results, good sources of information are essential. All manufacturers now have online access to this type of information. It is essential that proper documentation is used and that records are kept of the work carried out. For example (usually electronic version), X job cards X stores and parts records X manufacturer’s warranty systems These are needed to ensure the customer’s bill is accurate and also so that information is kept on file in case future work is required or warranty claims are made. Recommendations may also be made to the customer, such as the need for X further investigation and repairs X replacement of parts Or, of course, the message the customer would like to hear, that no further action is required!

Safety First Different manufacturers have different ways to re-energise the high-voltage system – you must refer to specific data for this operation. 1. 2. 3. 4. 5. 6. 7.

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Use appropriate PPE at all times. Unlock service connector. Refit the service connector. Switch ON the ignition. Check dashboard warnings. Connect scanner and check for faults. Remove the fencing and high-voltage warning signs.

Figure 8.17  Electronic scanner and data source

8  Maintenance, repairs and replacement Recommendations to your company are also useful, for example, to improve working methods or processes to make future work easier or quicker. Results of any tests carried out will be recorded in a number of different ways. The actual method will depend on what test equipment was used. Some equipment will produce a printout, for example. However, results of all other tests should be recorded on the job card. In most cases this will be done electronically, but it is the same principle. Key Fact Always make sure that the records are clear and easy to understand.

Safety First Some EVs require special handling when it comes to roadside assistance and recovery operations. Much of the information in these sections is freely available to first responders and is provided by Tesla Motors on its website (www.teslamotors.com/firstresponders).

8.5.2  Emergency start On some vehicles, even if the high-voltage battery has been discharged completely, there is still an option allowing the car to be restarted twice for a short distance. The eGolf, for example, has an emergency start function:

8.5 Recovery and roadside assistance

1. For approx. 100 metres, after switching the ignition off and on 2. For approx. 50 metres, after switching the ignition off and on once again

8.5.1  Introduction

No further emergency starts are possible.

Some EVs require special handling when it comes to recovery and roadside assistance operations. EV manufacturers provide detailed information and a number of other sources are becoming available such as phone apps.

8.5.3  Roadside repairs Roadside repairs should only be carried out by qualified personnel and by following all the safety and repair procedures outlined

Figure 8.18  Volkswagen eGolf on charge (Source: Volkswagen Media)

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8  Maintenance, repairs and replacement previously in this book. General information as well as more specific details are available.

8.5.4  Recovery For roadside recovery, many manufacturers provide roadside assistance numbers for the driver to call. In addition, detailed data sheets are provided that give information similar to the following instructions for transporters (provided by Tesla in relation to the Model S):

Figure 8.19  Key component and high-voltage information (Source: Tesla Motors)

phase current drive (electric drive motor/ generator). This connection cannot be undone without mechanical work. If the vehicle needs to be towed, there are usually two options (For example, these instructions for the Volkswagen eGolf): 1. Towing the vehicle with the high-voltage system intact: Switch the ignition On and engage the selector lever in the N position to allow electric freewheel mode. The vehicle can now be towed for a maximum distance of 50 km at 50 km/h using a rope or towbar. Using a bar for towing is recommended for safety reasons. 2. Towing with a damaged high-voltage system: If it is not possible to activate the high-voltage system, the vehicle must be transported with all four wheels stationary. Freewheel mode cannot be activated, as there is a risk of overheating. As a general guide, tow an EV slowly for a short distance to remove it and yourself from danger. Then suspend or use a flat bed.

8.5.6  Emergency response In an earlier section, I outlined some general aspects that are important for emergency personnel. All manufacturers supply detailed information:

Figure 8.20  General instructions and deactivation information (Source: Tesla Motors)

8.5.5  Towing Electric vehicles have a fixed connection between the drive wheels and the three-

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X model identification X high-voltage components X low-voltage system X disabling high-voltage X stabilising the vehicle X airbags and SRS X reinforcements X no-cut zones X rescue operations X lifting X opening Key Fact Most manufacturers supply detailed information.

8  Maintenance, repairs and replacement A good example of this material is available from Tesla Motors on its website: www.teslamotors.com/firstresponders

8.5.7  Fire A fire involving a BEV or HEV should generally be approached in the same manner as a conventional motor vehicle, although several additional factors should be considered. One approach indicating the basic steps that should be considered for extinguishing a fire involving any motor vehicle (including an EV or HEV) is illustrated in Figure 8.21: Vehicle extrication and rescue and/or vehicle fire involves key steps to stabilise and disable the vehicle. A vehicle may appear to be off, but there may still be a hazard for fire fighters. Emergency responders must always disable the vehicle’s ability to operate as per the vehicle manufacturer’s instructions.

Emergency response guides from vehicle manufacturers usually recommend a defensive approach to a battery fire. In other words, let it burn and consume itself. However, exposure to the heat and/or products of combustion must be considered. Methods for extinguishing a vehicle battery fire depend on many things such as type of battery, extent of fire, configuration and physical damage to battery unit (Figure 8.21). If water is used, copious amounts are normally required. However, this may be impractical if the vehicle and battery unit are not accessible and/or runoff is a concern. Some emergency organisations advise that for lithium-ion battery fires, extinguishment can be attempted using dry chemical, CO2, water spray or regular foam. Highvoltage batteries are well-sealed and do not contain much liquid electrolyte. Most spills can, therefore, normally be handled

Figure 8.21  Example of approach to vehicle fire extinguishment

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8  Maintenance, repairs and replacement high-voltage components. Always plan for the worst-case scenario. Figure 8.22 shows a fire blanket that can be used to completely cover a vehicle. Note this would control a fire but may not extinguish a battery fire. If a fire starts on an EV (or any vehicle), the fire brigade should be called immediately and normal fire procedures followed. EV specific guidance: If the vehicle is plugged in for charging, and it is safe to do so, it should be disconnected or the power switched off. Most fires on an EV should then be treated just like on an ICE vehicle. X The normal range of extinguishers can be used if it is safe to do so. X The vehicle (EV or ICE) can be covered with a fire blanket if it is safe to do so. X If a fire starts on an EV battery that has been removed from the vehicle, it can be covered with a battery fire blanket if it is safe to do so. If any of these steps have been carried out, then this should be communicated to the fire and emergency services.

Figure 8.22  Fire blanket to cover an entire car (Source: Eintac)

with an absorbent. As new battery designs and technologies are introduced, this basic approach may need to be re-evaluated. A further consideration is that built-in protection measures, which prevent electrocution from the high-voltage system, may be prevented from working properly. The normally open relays (contactors) for the high-voltage system could fail in a closed position if exposed to heat or if they are damaged. In serious accidents, short circuits to the chassis/body may become possible with the energy still contained in the high-voltage battery or any of the

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8.5.8  Damaged vehicle delivery An accident-damaged vehicle brought to the workshop should be X immediately marked with a red roofmounted warning cone X de-energised or checked for safety by a Level 3 qualified technician, using suitable PPE X offloaded and stored in the designated secure area X left for a number of days as a safety precaution before any further work is carried out There is a small risk that an EV battery could leak electrolyte, particularly if damaged. A dedicated spill kit must be provided and the instructions it contains followed if a spill occurs (Figure 8.23).

8  Maintenance, repairs and replacement

Figure 8.23  Battery leakage kit (Source: Eintac)

8.5.9  Accident and incident reporting

8.6.2  High magnetic strength components (motors)

All accidents and incidents involving hazardous voltages and/or hazardous substances must be reported via the accident reporting system. For all exposure incidents/accidents or dangerous occurrences which have (or could have) resulted in death, injury or occupational disease, the health and safety executive will need to be notified through the ‘Reporting of Injuries’ process.

These components should be handled like any other heavy item, but this should NOT be done by any person with a heart pacemaker or other medical device that may be affected by magnetism. The component should be in a fenced off area in the workshop or parts department. No additional precautions are needed. The old components should be packaged in the same way that the new one was delivered.

8.6  Transportation and storage

Transportation is by the normal methods for new and returned parts.

8.6.1  Electric vehicles Undamaged EVs should be treated like any other vehicle on the premises. If an EV is damaged, then it should be treated as outlined previously. EVs should only be transported on a flatbed truck.

8.6.3  High-voltage batteries When new and still packaged, these components should be handled like any other heavy item. Old or unpacked new batteries, modules or cells should be in a fenced off area

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8  Maintenance, repairs and replacement in the workshop or parts department. Only a qualified person should handle these items. The old components should be repackaged in the same boxes that new ones were delivered in, before being moved from the fenced off work area to the parts department or other designated storage area. When being transported the original packaging must be used together with the appropriate warning label (UN3480 is for batteries only, UN3481 is used if the batteries are part of another assembly). In most cases, a specialist shipping company should be used to transport batteries. This section is only intended as an overview of the issues. New lithium-ion battery handling labels and shipping marks have been effective, under changes to the International Air Transport Association (IATA) dangerous goods transport regulations since 1 Jan 2017. However, under the 60th edition of the regulations (1 January 2019), labels such as those shown as Figures 8.24 and 8.25 are mandatory. From 1 January 2020, manufacturers and subsequent distributors of lithium cells or batteries and equipment powered by lithium cells and batteries manufactured after 30

Figure 8.25  Mandatory label if the batteries are part of another assembly June 2003 must make available the test summary as specified in the UN Manual of Tests and Criteria, Revision and amend. 1, Part III, subsection. Before lithium cells/ batteries can be transported, they must have successfully passed certain tests. These tests simulate transport conditions like pressure, temperature, crush and impact and are described in the UN Manual of Tests and Criteria. Types of packaging are also specified in regulations as outlined in Figure 8.26. It is usually recommended that a specialist company be used for transporting batteries – particularly if damaged. Always refer to the latest information and regulations – this section is just intended as a guide.

8.6.4  Storage of cells and battery packs To mitigate risks previously noted, individual cells or completed battery packs should be stored in a lockable steel shipping/storage container. Only qualified persons should have access to the storage area. Figure 8.24  Mandatory label for batteries only

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The container must be positioned as far away from the main buildings as possible. If

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Figure 8.26  Lithium-ion packaging instructions taken from United Nations Economic Commission for Europe (UNECE) documentation the worst should happen the resulting fire should be contained long enough for the fire and rescue service to arrive. The container(s) will be suitably signed to notify of the contents. If it does become necessary to have any cells or battery packs stored inside during working hours, it is recommended that some or all of the following are observed: X Insulated covers must be used. X The items are positioned behind a sturdy barrier to prevent accidental damage from any workshop traffic (e.g., hand pump/pallet trucks or forklift trucks). X Cells or battery packs shall never be stacked in a way that could cause the external structure to become damaged or compromised in any way. X All ‘live’ cells or battery packs will be segregated and clearly labelled/signed as

such to adequately warn everyone in the facility of their presence. X The items are only moved by a qualified member of staff who understand the associated risks.

8.7 Recycling industry guidance Guidance has been produced for the recycling industry known as: Electric and Hybrid Vehicles – Recyclers Best Management Practice Guide. Before vehicle collection X Train drivers how to identify risks from these vehicles and processes required to make vehicles safe. X PPE and neutralising kit should be available to drivers at all times and they should have received training in how to use them.

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8  Maintenance, repairs and replacement X Identify electric and hybrid vehicles prior to collection. X Investigate type of incident and damage sustained (e.g., flood, fire, accident damage) X Assess likelihood of battery damage (e.g., has vehicle sustained damage to area of vehicle where battery is housed) and warn driver of potential risks. During vehicle collection X Utilise PPE. X Mark vehicle with appropriate warning signs. X Assess vehicle condition and damage sustained prior to loading vehicle. X Check battery status, including potential for any damage – inspect battery for physical damage, leakage or thermal incident (fire or discolouration of HV cables). X Telephone for advice if necessary. X Complete neutralisation of any spilt battery fluid. X If necessary, de-energise vehicle, following manufacturer processes. X If unsure – LEAVE IT WHERE IT IS and get a specialist. Vehicle on-site X Make suitable tools and PPE available. X Access vehicle information resource (see examples at end of section). X Reassess vehicle for potential HV battery or HV system damage – inspect battery for physical damage, leakage or thermal incident (fire or discolouration of HV cables). X Mark vehicle with appropriate warning signs. X De-energise vehicle, ALWAYS FOLLOW MANUFACTURER PROCESS – if unsure seek advice before de-energising. X Once de-energised, store vehicle in a quarantined area, on flat ground or suitable racking. X Train staff how to handle vehicle correctly to avoid any further damage to HV systems and allow only trained staff to work on vehicle until it is deemed safe.

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X If flood-damaged, lift one end of the vehicle to drain as much water as possible prior to storage. X Make vehicle watertight prior to storage. Dismantling X Make suitable tools and PPE available. X Never work on vehicle alone – always have colleagues around ‘just in case’. X Manual handling guidelines must be followed. X Follow manufacturer’s guidelines or other resource (see examples at end of section) when dismantling vehicle. X Allow only trained staff to work on vehicle until it is deemed safe. X Store battery appropriately in a restricted access area – never mix battery types, store in the same orientation as when in the vehicle, store in such a manner that they cannot fall, or have anything fall on them. Resources X IDIS (www.idis2.com) X NFPA (www.nfpa.org) X EINTAC (https://eintac.com) X Automotive Recyclers Association – ARA University X individual vehicle manufacturers Note: This is a guide and template only. All vehicle recyclers are advised to complete their own risk assessments and best management practices that are suitable for their specific requirements, operating practices, local rules, legislation, training and standards. This guide and lots more useful information relating to dismantling and recycling is available from Salvage Wire: www.salvagewire.com.

Note 1 https://www.ofcom.org.uk/news-centre/2021/ spectrum-mystery-leaves-shoppers-stuck-incar-park

CHAPTER

9

Diagnostics 9.1  Diagnostic operations

9.1.2  Live data

9.1.1  Introduction

For the live data examples in this section, I used a TopDon ArtiPad or the later Phoenix version. More details are available from: www. diagnosticconnections.co.uk.

This section is designed to not only give an overview of how to carry out this type of work but also what is actually possible. Note, you must do proper training and be qualified before carrying out any work on high-voltage systems. This is for your own safety as well as the vehicle’s driver and passengers.

Scanning for live data on a vehicle is just as important as scanning for diagnostic trouble codes (DTCs). Usually, a DTC is the first step and then live data is the second. In this

Safety and information Electric vehicles (EVs) have X high-voltage components and cabling capable of delivering a fatal electric shock X stored electrical energy with the potential to cause an explosion or fire X components that may retain a dangerous voltage even when switched off X the potential to affect medical devices such as insulin pumps and pacemakers Before working on EVs, you must X be qualified to the appropriate level (and ideally IMI TechSafe™ registered) X refer to the vehicle manufacturer’s information X use all equipment in accordance with its safety instructions IMI TechSafe™ The Electricity at Work Regulations (1989)1 state that: ‘No person shall be engaged in any work activity where technical knowledge or experience is necessary to prevent danger or, DOI: 10.1201/9781003431732-9

9 Diagnostics

where appropriate, injury, unless he possesses such knowledge or experience, or is under such degree of supervision as may be appropriate having regard to the nature of the work’. IMI TechSafe™ registration covers this requirement and further ensures that complex automotive technologies are safely and correctly repaired by qualified technicians. To be registered as IMI TechSafe™, you must: X successfully complete an appropriate qualification or IMI Accredited solution X join the IMI Professional Register X complete CPD from a specified range to maintain professional registration

section, we will look at a few examples of the information that is available relating to the highvoltage battery. The screenshots shown as Figures 9.2 to 9.15 just scratch the surface of what information can be accessed from the vehicle. However, they serve to give a good overview of the process, whether the vehicle is ICE or EV or, in this case, both as it is a PHEV. Safety First You must do proper training and be qualified before carrying out any work on high-voltage systems.

Figure 9.1  Phoenix Pro scanner

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Figure 9.2  This is the main menu screen where in this case I will choose the Intelligent Diagnosis option.

Figure 9.3  The scanner then connects to the Bluetooth vehicle connection interface (VCI) that I have already plugged into to car’s data link connector (DLC). It then automatically scans for the VIN and, if found, sets the scanner up appropriately for the vehicle. In this case a 2018 Volkswagen Golf GTE. I then select the Diagnostic option.

9 Diagnostics

Figure 9.4  The scanner now interrogates the network to see what is connected to it and displays a list of the various systems. I next select option 8C Battery Energy Control Module.

Figure 9.7  The screen now shows a very long list of the parameters that are being monitored and can be displayed as live data. For example, you can see here that there are eight temperature sensors on the battery pack. This data could be very useful if you were looking for a specific fault in the battery.

Figure 9.5  It then takes a minute as the scanner interrogates the specific control system. Figure 9.8  I have scrolled down the list here, and, for example, you could now select to view high-voltage battery current and voltage readings.

9.1.3  Insulation testing An insulation tester is mostly used on electric and hybrid vehicles to check that the highvoltage cables and components are safe (see also Section 2.5.3). Figure 9.6  Now we have the options as displayed here. The two of interest for now are 02 Read DTC and 08 Read Data Stream (live data). I select Read Data Stream.

The device shown as Figure 9.16 is known as a Megger and can supply up to 1000 V to test the resistance of insulation on a wire or component. A reading well in excess of 10 MΩ

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Figure 9.9  Scrolling down further allows you to select Charge State, Cell 01 to Cell 96. I have just selected four of them for now. Scrolling down once again allows you to select Cell 01 to Cell 96. These are the voltages of each cell in the battery pack. I have again just selected four of them for now. I also selected H-V Battery voltage and temperature on the screen we looked at previously.

Figure 9.10  Pressing OK now displays the chosen live data. In this case, it is showing the battery voltage as 387.2 V and the state of charge (SOC) of Cells 01 and 02 as 93%. Cells 03 and 04 were the same. The symbols on the right allow you to plot the data as graphs. Alternatively, pressing Record will keep a record of the figures over time. is what we would normally expect if the insulation were in good order – but as always, check manufacturer’s recommendations. The high-voltage is used because it puts the insulation under pressure and will show up

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Figure 9.11  Graphing is very useful if you want to monitor how the live data changes over time or even as the vehicle is being driven.

Figure 9.12  Going back one step and scrolling down we can see the voltages of Cells 03 and 04 display to 3d decimal places. Both are 4.026 V in this example. Comparing cell voltages across all 96 of them is a great way to track down a fault. The figures on this car were all within a few tens of millivolts – so all is well!

faults that would not be apparent if you used an ordinary ohmmeter. Key Fact Insulation testers use a high-voltage because it puts the insulation under pressure to show up faults that would not be apparent with an ohmmeter.

9 Diagnostics

Figure 9.13  After returning to a previous menu. I then scan for faults in the Battery Energy Control Module. None were present.

Figure 9.15  The four faults are all noted as passive faults so not serious enough to illuminate the warning light. More work for another day perhaps! Pressing the Report button will save this list so you can keep this information for your customer.

Figure 9.14  Finally, I scanned for DTCs (fault codes) across the whole vehicle. It is recommended that before any work is carried out on a vehicle that a full DTC scan is carried out. This is evidence of the state of the vehicle before you work on it. Doing another scan after work is complete shows you have repaired a fault and/or not created anymore. Four faults showed up.

To test the insulation resistance on the stator shown as Figure 9.17, the Megger should be connected between one of the three phase windings and the iron body. Take care when using insulation testers. The high-voltage used for the test will not kill you because it cannot sustain a significant current flow, but it still hurts!

Figure 9.16  Megger insulation tester

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Figure 9.18  AVL HV Safety 2000 Figure 9.17  Stator from a hybrid motor

9.1.4  Equipotential bonding In the UK aftermarket, it is not custom and practice to carry out an equipotential bonding (EPB) check, but in some EU states, Germany and Austria, for example, it is. Should we be doing an EPB check after EV repairs or service here in the UK? I will review the equipment later, but first let’s learn more about EPB and how it relates to EVs. EPB is the process of electrically connecting metalwork and conductive parts of various components so that the voltage is the same throughout these various parts (an equal potential). EPB is used to reduce the risk of equipment damage and personal injury. It is sometimes simply referred to as bonding and is commonplace in domestic and industrial electrical installations. Its main purpose is safety. In the near future, all workshops and garages will have to deal with a significant number of high-voltage electric vehicles (EVs). Guaranteeing the safety and reliability of vehicle high-voltage systems is something we will need to become more familiar with. Training, qualifications and CPD to maintain registration will be essential. EVs use an insulated return system such that there is no connection between the high-voltage circuits and the chassis. As part of the startup process (when the vehicle is switched into Ready mode), the on-board insulation monitor device is checked. Some

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manufacturers also carry out the check frequently during vehicle’s operation phase. If a failure of this ‘monitor’ is detected, then the vehicle will not switch on – providing everything else is working as it should. However, if an insulation fault occurs on an HV component (e.g., AC compressor, heating device) that is not properly connected to the EPB system, the insulation monitor is not able to find and monitor this hazardous issue. When repairs are carried out, the insulation resistance or isolation strength of high-voltage system components is always performed by the technician. The continuity of cables, including the braided shielding, is also tested. A value of 500 V is often used for this test, but for some systems, it is becoming necessary to use 1000 V, but this is not always available from some testers. To date, here in the UK anyway, the bonding (equipotential bonding) resistance between the components and chassis has not been carried out as a matter of course – other than as a physical ‘hand-and-eye’ check. The reason that all the components are bonded to the chassis is so that even if insulation faults occur, the potential (voltage) difference between all the main metal components will always be zero – so no electric shock will occur. In theory, this should never happen so the bonding is like a belt and braces approach – better safe than sorry though because the high-voltages used can be fatal. It is also

9 Diagnostics

Figure 9.19  EV system block diagram showing main components and chassis equipotential bonding important to note, as mentioned previously, a possible insulation fault can only be monitored if no EPB faults are present. At this point, we should once again remind ourselves of Murphy’s Law: If it can go wrong, it will go wrong! It is becoming more common for technicians working on vehicles to be required to prove

Figure 9.20  This bonding strap connects the case of a high-voltage component to the chassis on a Volkswagen Golf GTE

that certain things have been carried out, for example, recalibration of the advanced drive assistance systems (ADAS) after a new steering component has been fitted. These checks or calibrations are now being specified as an insurance industry requirement (IIR) after major accident repairs have been completed.

Figure 9.21  A bonding strap between the battery box and chassis on a Nissan LEAF

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9 Diagnostics A trained technician will always perform tests on a vehicle to make sure it is ‘made safe’ or ‘de-energised’ before any work is carried out that may involve the high-voltage system. This is different from when the question is asked by the vehicle owner or driver.

2. The HV component and an adjacent conductive part is less than 20 mΩ. 3. Between two HV components that are simultaneously accessible for a person and are arranged in a distance up to 2.5 m in the vehicle shall be less than 100 mΩ

The vehicle runs through checks every time it is switched into Ready mode. A technician carries out more tests during or after repairs have been done, including electrical and physical checks. But how do you prove this has been done, particularly if something safety-related does go wrong with the HV system at a later date? Note that isolation strength (insulation resistance) of some components can deteriorate over time.

The requirement that is important in the aftermarket (Number 3) is that the resistance between all exposed conductive parts and the chassis must be lower than 0.1 Ω (100 mΩ) when at least 200 mA is flowing.

For some organisations, these sort of measurements and records are becoming more important. For individual technicians, it is also becoming important that they are guided through the tests so they can prove all tests have been carried out and prevent litigation.

Note that to measure milliohms (mΩ), special equipment is needed; a normal multimeter is not suitable. EPB is used to reduce the risk of equipment damage and personal injury from high-voltages.

The UN regulation ECE R100 is titled: Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train. There are two main parts to this in relation to high-voltage safety, as represented by Figure 9.22. The specified equipotential bonding, low electrical resistance requirements are 1. The HV component and the vehicle body shall be less than 40 mΩ.

Figure 9.22  ECE R100 requirements

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Figure 9.23  AVL DiTEST HV Safety 2000

9 Diagnostics Checking EPD can be more involved than it may first appear. However, with the proper equipment, suitable training and time, it is very easy. Checking that the EPB is meeting regulations is something that could become more common as more high-voltage vehicles hit our workshops. Measuring and recording EPB resistance will require a set process and suitable equipment. The AVL DiTEST HV safety equipment, a CAT III device, could be one solution. This high-voltage measurement equipment guarantees the verification of all safety requirements for DC high-voltage (HV) circuits

on the vehicle. This computer-based test equipment is able to perform measurements according to UNECE R100. It supports the requirements of an EPB measurement with a current of 1 A. The equipment is powered from the USB port, no additional power supply or batteries are needed and no range selection is required, reducing the potential for errors. After following ALL appropriate safety instructions, a fully trained EV technician can carry out a number of tests and is guided through the process using the equipment specified in Table 9.1 (after the initialisation/self-test):

Table 9.1 Features of the AVL DiTEST HV Safety 2000 All-pole DC voltage measurement

The absence of a voltage is verified. This is performed by a menu-driven measurement of the three relevant voltages: 1. Voltage measurement HV+ against HV2. Voltage measurement HV+ against the chassis 3. Voltage measurement HV- against the chassis

DC voltage measurement

This mode is used to measure any DC voltage (up to 1000 V)

HV insulation measurement

Tests for insulation resistance by applying a high-voltage of up to 1000 Vt

Equipotential bonding

The device generates a test current of up to 1 A. This current loads the bonding conductor accordingly so that faults can be detected. The test voltage generated for this is respectively low so that the measurement does not create a hazard. •

Range: Measuring currents 100 to 1000 mA

•

Resolution: 1 mΩ

•

Tolerances: ± 3.5% v. M (of the measured value)

Resistance measurement

Resistors in the range of 1 mΩ to 10 MΩ can be measured

Diode test

Diodes can be tested in the forward direction and reverse direction. Open and short circuit states are determined and displayed

Capacity measurement

In this mode capacitors can be measured in the range 1 nF to 300 μF

Insulation monitor check

The function of the insulation monitor in a HV vehicle is tested and the trigger threshold determined. For this purpose, a series of voltage measurements between HV+ and the chassis are performed, whereby at each voltage measurement the internal resistance of the HV Safety 2000 is gradually decreased by steps

Insulation resistance

This function is used to measure insulation resistance in accordance with the recommendation of SAE J1766: www.sae.org/standards/content/j1766_201401/

Full measurement

This mode combines the following measurements into one user-guided procedure: 1. Prepare vehicle for the measurement 2. Verification of zero-potential 3. 3 HV Insulation measurement at the zero-potential system 4. SAE J1766 measurement on the live system

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9 Diagnostics To use the system, the technician creates a profile, which can be password-protected. Before testing, the vehicle details are also entered. This is all saved and can be reused. After each measurement, a detailed results protocol can be generated. By activating an Automatic Save function, a result protocol is generated and saved automatically after each measurement. The documented results, which are dated, linked to the vehicle and technician and saved, are a key feature. This is robust proof that tests have been carried out by a specified person using calibrated equipment at a specific date and time. The first step is to enter the technician’s details or select yourself from the list if already done. Then the vehicle details are entered or, again, selected from a list of already done. After completing technician and vehicle details, clicking the Diagnostics button shows the test/ check menu.

Figure 9.24  Create vehicle dataset screen

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The step-by-step guidance in the program was very easy to follow and ensured all stages of the tests/checks were covered, including calibration. Other than difficulty accessing HV+ and HV- on some vehicles, which, of course, is the case regardless of the equipment in use, all the tests were easy to carry out. On most vehicles, to access HV+/HV-, the inverter cover needs to be removed. Arguably, many of the checks could be done with a good multimeter and insulation tester, but, of course, this does not automatically keep a written record. Not applicable in the UK at this time, but according to German and Austrian legislation, a multimeter is not allowed for this test because of the potential to adjust the voltage range or connect the leads incorrectly. A two-pole tester is recommended by some organisations. An exact copy of the SAE J1766- and ECE R100-based tests was not possible without the AVL equipment. The EPB testing was the most interesting check and is definitely not possible with a normal multimeter.

9 Diagnostics In principle, the test is very simple. A known current (up to 1 A as per ECE R100 requirements) is made to flow and the voltage is measured. The resistance is then calculated. Before this, if using standard leads, the system is calibrated or zeroed to ensure accuracy.

and dirty. We chose to connect one lead, as shown in Figure 9.26, after scratching a small amount of paint off (which will be replaced!). In this way the connection is to the actual pack rather than a bolt or strap. Polarity in the test is not important.

If the optional Kelvin leads are used, then no calibration is needed because the voltage at the test points is measured using a separate circuit to the one where the current is flowing. The Kelvin crocodile clips (Figure 9.25) have both jaws insulated from each other and are attached to a twin-core insulated cable.

One option for the other lead was the bolt as shown in Figure 9.27, but our decision was that we couldn’t be absolutely certain that this was connected to the chassis. It could just be contacting the strap. In Figure 9.28 we cleaned the bolt and made the connection as shown. In this way, if the

One challenge, which is a little more complex than it first seems, was where to connect the test leads. To even see the battery pack on a Nissan LEAF, for example, a large protective cover has to be removed – it’s not difficult, but it does take time. The pack is painted, and as this is an older car, so it is also a little corroded

Figure 9.26  Kelvin probe connected to the battery pack

Figure 9.25  Kelvin lead crocodile clip showing insulated connections

Figure 9.27  One option for connection that was NOT used (There are 4 of these bonding straps on the battery pack)

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9 Diagnostics automatically created report can be printed out, and an example is shown as Figure 9.30. You can see in this report that one test failed, but the next one passed. It is okay to try the test a few times if the result is a failure. This is because it is very easy to make a poor connection accidently but not possible to achieve a pass accidentally – so one good result means the resistance is within specs.

Figure 9.28  Chassis bolt connection result was as required (less than 100 mΩ) when we did the test, it would definitely prove a low-resistance circuit between the battery case and the vehicle chassis. Our result was 5 mΩ so well within specifications.

9.2 Diagnostic tools and equipment 9.2.1  Introduction Diagnostic principles are the same for low or high-voltage vehicles, but there are additional issues that we must consider, not least of which is safety. We will look at

Checking the EPB on the motor of the vehicle shown in Figure 9.29 was easier to access and connect. One connection to the lowvoltage battery negative terminal and one to the body of the motor after the area was cleaned. Again, we got a very low result of 8 mΩ.

X tools and equipment (what is needed and examples of its use) X non-invasive testing (what can be done without any dismantling) X invasive and more in-depth testing (getting deeper into waveforms and how to interpret them)

Overall, after a little practice because the equipment was unfamiliar at first, the checks were very easy to carry out. The

9.2.2  De-energisation procedures Before carrying out any work on an EV, it may be necessary to switch off the high-voltage system. This is described in different ways by different manufacturers (de-activation or isolation, for example). Manufacturers also have different ways to de-energise the high-voltage system so to be certain you are carrying out the process correctly, you must always refer to their specific data. Here I have presented a reminder of a typical but generic example of a de-energisation process:

Figure 9.29  Motor body connection on the Renault Zoe

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 1. Use appropriate PPE at all times and place high-voltage warning signs and a fence around the vehicle with posts and barrier tape.  2. Disconnect the charging plug.

9 Diagnostics

Figure 9.30  Example report showing that the first test failed  3. Switch ignition ON, connect scanner, check for faults and check high-voltage readings are normal.  4. Switch OFF the ignition.  5. Remove the service connector (this can be a low- or a high-voltage device).  6. Lock service connector to prevent accidental re-connection.  7. Switch ON the ignition and check dashboard warnings.  8. Connect scanner and check high-voltage readings are ZERO.

 9. Switch OFF the ignition and remove the key to a safe place (at a distance if a remote key) 10. Prove correct operation of a Cat III (minimum) multimeter or a two-pole tester on a low-voltage source, then check for ZERO voltage at the inverter and/or battery output. Step 10 of the generic de-energisation process is where the first and most important test is made.

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9 Diagnostics

Figure 9.31  Volkswagen service/maintenance connector breaks the pilot line, which opens the main contactors

Figure 9.33  Two-pole tester and the four possible results (part of the PicoScope EV kit)

9.2.3  Two-pole tester

1. Leads open circuit – nothing is displayed. 2. Leads shorted together – zero is displayed in red and an alarm sounds (Test). 3. Leads connected to a voltage between 3 and 36 V – voltage value is shown as AC or DC and the display is blue (Go). 4. Leads connected to a high-voltage above 36 V – voltage value is shown as AC or DC, the display is red and an alarm sounds (No-Go).

A voltage tester (Figure 9.33) has one job – it effectively says ‘Go’ or ‘No-Go’. It could be the piece of equipment that takes the most important reading – the one that stops you being killed by high-voltage electric shock. This device is deliberately very simple. It has one button to switch it on that also illuminates a handy light, and it will display one of only four possible results:

Figure 9.32  Nissan LEAF connector removed from a panel under the rear seat. This breaks the high-voltage battery circuit in the middle of the battery pack, effectively halving the highvoltage risk as well as isolating it from the rest of the car.

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Testing for a zero-volt potential requires a dedicated measurement routine to ensure beyond a reasonable doubt that the results are accurate and verified. You can, of course, use a suitable CAT III multimeter to do this test. However, there is a potential for error because of the many settings and connections on a multimeter. For example, what happens if you apply a multimeter to the correct high-voltage test points of a vehicle, but you have set the dial to display AC voltage or the leads are in the wrong ports on the meter? In both cases, the multimeter could read either low or no voltage suggesting the vehicle is safe to work on – when it isn’t!

9.2.4  Multimeter and insulation tester Multimeters and insulation testers can be separate pieces of equipment, but many are

9 Diagnostics

Figure 9.34  Simple low-voltage test (but importantly a check of the meter and leads)

Figure 9.36  Cheap but very useful amp clamp multimeter

the heater switched on. More about what this reading means in the next sections.

9.2.6  Oscilloscope

Figure 9.35  Insulation resistance test between a charger connection and the vehicle body. The reading here is over 1000 MΩ so well within specifications now combined into one device (Figures 9.34 and 9.35). Multimeters used for high-voltage work should be a minimum of CAT III.

9.2.5  Amp clamp A simple and cheap device is shown as Figure 9.36. It is a CAT II multimeter, so it is not appropriate for EV testing. However, using the amp clamp is noncontact so no high-voltage reaches the device. The reading shown in Figure 9.36 is the current flowing from the high-voltage battery with the car stationary but

There are several types of oscilloscope designed specifically for automotive diagnostics. My favourite by far is the PicoScope. Now even better, Pico has produced a kit specifically for high-voltage systems. The kit is based on the PicoScope 4425A with PicoBNC+® technology, which powers devices such as the amp clamps directly from the main unit – no batteries needed. EV guided tests, along with all the normal ICE systems, are available in the free PicoScope Automotive software. Some examples of the EV guided tests are as follows: X DC high-voltage energy system and the AC motor/generator drive system X charging behaviour and 12 V/high-voltage battery current split issues X CP/PP communications between charging system and vehicle X three-phase current measurements to check winding balance under load Some of these tests will be covered in the next sections. Because Pico, like the IMI, support the requirement that technicians are properly trained and qualified, the EV guided tests are

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9 Diagnostics point on the vehicle to prevent transient voltages from damaging the scope. Instructions for differential probes may imply that some oscilloscopes are grounded (earthed) through the mains connection. A USB oscilloscope connected to a laptop is unlikely to be grounded even if it is powered from the mains. However, for on-vehicle measurements, it is important to distinguish between earth as in the ground we walk on and chassis ground or earth on a vehicle. It is the vehicle ground that should be used for EV testing. Figure 9.37  Top of the range PicoScope kit specially designed for EV diagnostics – note the three current clamps that can be used on each phase of the motor/generator circuit

As with ICE systems, a scanner is an essential piece of EV diagnostic equipment. There are two main parts to its abilities:

only available in the dedicated PicoScope software.

X reading diagnostic trouble codes (DTCs) X displaying live data

9.2.7  Differential probe

DTCs identify a specific problem area and are a guide as to where a fault might be occurring within the vehicle. High-voltage system DTCs are displayed in the same way as any others. Likewise, live data can be shown on the screen, for example, battery voltage and even individual cell voltages in the traction battery.

An active differential probe allows high-voltage measurements, which an oscilloscope alone would not be suitable for. The probe shown is CAT III, rated up to 1000 Vrms and has a 25 MHz bandwidth. The voltage rating applies to its 1/20 and 1/200 (attenuation) settings. This differential probe has an auxiliary grounding terminal. It is very important that this terminal is connected to a reliable ground

Figure 9.38  Active differential probe

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9.2.8  Scanner

In the next sections, we will look in more detail at some of the useful information that is available to assist with EV diagnostics.

Figure 9.39  Scanner connected to the DLC using a Bluetooth dongle

9 Diagnostics 9.2.9  Summary There is still some debate in our industry about how many EVs (including HEVs, PHEVs and FCEVs) we will see in our workshops in the short term. What is certain is that in the medium and longer term, they will become very common. The right training and the right equipment for accurate and safe diagnostics will be essential.

9.3  Non-invasive measurements 9.3.1  Introduction Taking a measurement and then reacting to it as part of a logical diagnostic routine is how to find faults in vehicle systems, EV or otherwise. In other words, test don’t guess! An aspect sometimes overlooked, however, is how the act of taking a measurement can change the value of the thing that you are measuring (known as the measurand). For example, a test lamp on a sensor circuit would load the circuit and change the values – or worse, damage the system. Even a multimeter set to measure voltage can load a circuit by drawing a small current, which changes the reading accordingly. This is known as an invasive or intrusive measurement, where the act of measuring changes the circuit so an incorrect reading is obtained. However, good quality multimeters have a very high internal resistance (10 MΩ or more) so have a negligible effect.

known good waveform with the one you are currently viewing, to a voltage you measure on pin ‘99a’ of an ECU compared to the figure in manufacturer’s data – for example. This is the right way to work as it is an important part of the diagnostic process. If the voltage on pin ‘99a’ reads 12.4 V and data says 12.3 to 12.7 V, then you can be confident that you have a correct reading and take the next step. However, what do you do if the reading you take is 12.2 V? Or what if the waveform is just slightly different from the known good one? Sorry, no perfect answer to this one! You will need to use your experience. One key thing, though, is to consider how accurate your readings are and how much effect a small variation would have. In the example given, 12.2 V would be okay with me – but I would keep it in the back of my mind, just in case.

9.3.3  COP and signal probe The coil-on-plug (COP) and signal probe from Pico Technology is the easiest and fastest nonintrusive way to check COP ignition coils and spark plugs. However, it is also now very useful for EV systems. For example, to check the charger operation, it is only necessary to hold the probe near the charging plug (Figure 9.40) and a 50Hz signal

A non-invasive measurement is one where the instrument has no effect on what is being read. For example, a current clamp around a wire is one type of noncontact measurement. Another example is the coil-on-plug (COP) probe. Both of these are covered in more detail later.

9.3.2  Known good waveforms and measurements ‘Known good’ a phrase we often use when diagnosing faults. These measurements range from comparing the details of a

Figure 9.40  COP probe on the charging plug

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9 Diagnostics Figure 9.43 shows the current being consumed by the positive temperature coefficient (PTC) heater on a vehicle. In this example 15.7 amps. As I varied the temperature settings, the current changed accordingly – a quick and easy way to test this circuit.

Figure 9.41  COP probe on the on-board charger input

An interesting aspect of this test is to calculate the power consumed. Power equals voltage multiplied by current: P = V ×I = 380 ×15.7 = 5966W or about 6kW Electric vehicle batteries are rated in kilowatthours. For example, the battery on my PHEV is rated as 8.7 kWh but with a useable value of about 7.8 kWh (Lithium-ion batteries are never

will be shown (Figure 9.42). On this trace you can also see when the charger switched off. Tests can also be done on other parts of the circuit, but if the cable is very well shielded, the reading is much smaller. One thing to watch out for is that the probe is very sensitive.

9.3.4  Current flow: HVAC Measuring the current flowing from the highvoltage battery is simple with an amp clamp. This can be done using a meter with a built-in clamp (Figure 9.43), a meter with a separate clamp, or an oscilloscope as outlined later.

Figure 9.43  Clamp-type ammeter reading the current taken by the car heater

Figure 9.42  A 50Hz waveform from the charging plug via a COP and signal probe

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9 Diagnostics fully charged or fully discharged in order to extend their usable life). The kilowatt-hour is a composite unit of energy equal to one kilowatt (kW) of power sustained for one hour. Going back to the heater consumption. If this was running for one hour, then it would use 6 kWh – which is a significant proportion of the available 7.8 kWh. It is unlikely that I would need the heater on full power constantly, but it does show why using the heater on an EV causes the available range to drop.

9.3.5  Current flow: motor Measuring the DC current flowing from the high-voltage battery as the vehicle is being driven is a little more difficult than the simple amp clamp meter but not much! For this non-invasive measurement, I will measure the current consumption while driving and the regeneration while braking (decelerating). I connected an amp clamp around the main high-voltage supply cable as shown in Figure 9.44. Then with some cunning routing of its wire from under the bonnet, through the

Figure 9.44  One of the three amp clamps supplied in the PicoScope EV kit connected around the high-voltage battery supply cable at the inverter passenger window to the PicoScope, I could set my laptop up on the passenger seat. The PicoScope vertical scale was set to 40 A/div and the horizontal timebase was set to 10 s/div. A short journey of about 90 seconds, which included normal driving, hard acceleration and braking is shown as Figure 9.45. Where the trace is above the

Figure 9.45  Waveform showing the current consumption and regeneration plotted over about 90 seconds while driving

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9 Diagnostics zero line, current is being consumed, when the trace is below the zero line, the battery is being recharged. The peak current was about 250 A and the average current while driving normally on a housing estate road was about 20 A. Let’s do another quick calculation here to illustrate another important point:

Use the best and most appropriate test equipment, and as you become familiar with what readings you expect to get on different EV circuits and you follow a logical process, then diagnostics becomes much easier.

9.4  Charging testing

P = V ×I = 380 ×250 = 95,000Wor about 95kW

9.4.1  Protocol

If this was sustained for just 3 minutes (95 x 0.05 hours) it would consume 4.75 kWh, which is more than 60% of the battery capacity on this car. Further, under these extreme conditions, the efficiency drops considerably, too, further compounding the problem. This shows how consumption and, therefore, range is affected by driving style. It has the same effect on an ICE car but is less noticeable because of the much larger fuel quantity and range.

The charging system of an EV is built around standards set by the SAE, known as J1772. The J1772 connector (called the Mennekes in Europe) is designed for single-phase electrical systems with 120 V or 240 V but, with the addition of two extra pins, can also be used with three-phase. The car is connected to an electrical vehicle supply equipment (EVSE) unit that sits between the mains supply and the vehicle. This unit is in communication with the vehicle (when plugged in), which is also defined by the standard.

9.3.6  Summary Contactless and, therefore, non-invasive measurements have a number of advantages on an EV. These are X safety – no high-voltage is exposed X accuracy – the circuit is not affected X speed – quick and easy to connect

Figure 9.46  PicoScope 4425A (visit www. picoauto.com for more information)

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Figure 9.47  Connector has seven pins if threephase and five if only single phase: Proximity (PP), Protective earth (PE), Control pilot (CP), Line 1 single phase (L1) and neutral (N), Lines L1, L2, L3 and neutral are used for three phase (Source: Mennekes)

9 Diagnostics 9.4.2  Communication

Table 9.2  Status settings

The signalling protocol has been designed so that the EVSE and vehicle can communicate; for example, the charge rate required is determined by the vehicle – up to the limit of what the charger can supply. As the cable is plugged in, the following process is initiated (control pilot functions):

Base status

Voltage, CP-PE (V+/-1)

Charging status

A

0 (car) 12 (EVSE)

Not connected

B

9

Vehicle connected

C

6

Ready for charging

D

3

With ventilation

E

0

No power (shut down)

X Supply equipment detects vehicle is plugged in. X Supply equipment indicates to vehicle readiness to supply energy. X Vehicle ventilation requirements are determined. X Supply equipment current capacity is provided to vehicle. X Vehicle commands energy flow. X Vehicle and supply equipment continuously monitor continuity of safety ground. X Charge continues as determined by vehicle. X Charge may be interrupted by disconnecting the plug from the vehicle.

F

-12

Error

At the start of this process, the EVSE puts 12 V on the control pilot (CP) line. On the vehicle, the CP line is permanently connected to the protective earth (PE) via a 2.74 kΩ resistor. This makes the voltage drop to 9 V when a cable is connected, which also starts a 1 kHz pulse-width modulation (PWM) wave generator. Charging is activated by the vehicle adding a 1.3 kΩ resistor in parallel. This results in a voltage drop to 6 V; alternatively, a 270 Ω resistor is used for a required ventilation, resulting in a voltage drop to 3 V. The charging station monitors the voltage on the CP-PE loop. A diode is used in the circuit to make voltage drop in the positive range. A negative voltage indicates a fatal error (like touching the pins), and the power will be switched off. The status settings are shown as Table 9.2: EVSE and vehicle handshake sequences are not always the same. However, there is always a change of state between state B, where the

PWM signal peak is at 9 V, and state C, when it drops to 6 V and the vehicle initiates charging. The PWM duty cycle of the 1 kHz CP signal indicates the maximum allowed mains current. Type 2 devices can also have signals such as LIN or single wire CAN superimposed on the CP line at around 5% duty cycle, and this can set the charge rate. This may make the signal waveform look different and the current may not be as expected. PWM duty cycles are shown in Table 9.3. On some vehicles, all the decisions and settings of charge rate are determined by the on-board charger.

9.4.3  Breakout box To make connections to the charging circuit between the car and the charger, it was necessary to build a breakout box. I am sure these will become available soon if not already. The one shown is a Type 2 for single phase only. Table 9.3  Duty cycles PWM duty cycle (%)

Current (A)

10

6

20

12

30

18

40

24

50

30

66

40

80

48

90

65

94

75

96

80

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9 Diagnostics at a voltage of 244.6 V, which was connected via a x200 differential probe to isolate highvoltage from the PicoScope. It was a sunny day, and my solar PV panels are the reason the voltage is higher than the normal 230 V mains. The red trace shows the CP line 1 kHz signal at a maximum voltage of 6 V, indicating that charging is taking place.

9.5  Three-phase testing 9.5.1  Operation Figure 9.48  Homemade breakout box (green PE, yellow CP, black N, red L1 vehicle, red L1 EVSE to allow ammeter connection)

9.4.4  Charging waveforms Using the breakout box (Figure 9.49) I connected the EV Automotive PicoScope to the CP line, the mains voltage supply (L1) from the EVSE and also the current in the highvoltage battery cable using an amp clamp. The blue trace shows the current flowing to charge the battery. In this case about 9 A. The green trace shows the mains supply 50 Hz AC

It is acceptable to describe the electrical supply from the inverter to the motor as a three-phase AC sinewave. Likewise, the regenerative current from the motor (during deceleration/ braking) can also be described in a similar way. This is because, for most purposes, this is fine and helps us to understand the basic operating principles of an electric drive (simplified): 1. Driver demands power by pressing the accelerator the pedal. 2. Battery high-voltage is inverted into threephase AC to drive the motor. 3. Driver demands braking by pressing the brake pedal. 4. Car momentum drives the motor as a generator, which produces three-phase AC. 5. This is rectified into DC and used to charge the battery. In reality, the waveforms are slightly different due to the way they are created. In Figure 9.51 you can just see the small step changes and a ripple. This waveform was captured using three current clamps on the three phase wires connected from the inverter to the motor.

9.5.2  Motor drive waveforms

Figure 9.49  EV PicoScope connected to the breakout box CP line and mains AC supply and via an amp clamp on the main high-voltage battery supply cable. High-voltage protection gloves were used when making the live connections.

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Figures 9.52, 9.53 and 9.54 show the waveforms captured as the car was being driven. The first image shows acceleration from zero, then a steady speed, then accelerating again to a higher speed. The second image shows gentle deceleration (coasting down) and at the end the drop is where I touched the brakes and regeneration

9 Diagnostics

Figure 9.50  PicoScope waveforms captured on the CP line, L1 voltage and the current flowing to the battery

Figure 9.51  Three phase signals each offset by 120 degrees (zoomed in and superimposed)

was initiated. Regeneration reverses the current flow. It doesn’t cause the drop in voltage, which in this case was simply because the required braking was small. The third image shows a gradual decrease almost to zero speed during which time regeneration continued. The actual brakes were not activated. The frequency of the signal decreased as the vehicle came to a stop.

9.6 Batteries 9.6.1  Battery repairs EV battery packs can be repaired in two main ways, depending on the type of repair needed and the specific circumstances: 1. Cell replacement: EV battery packs consist of multiple individual cells, and if a particular cell becomes faulty or degraded, it can

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9 Diagnostics

Figure 9.52  Accelerating from rest (frequency is about 120 Hz)

Figure 9.53  Decelerating gently and then regenerating at the end

Figure 9.54  Regeneration reducing the car to low speed

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9 Diagnostics be replaced. In this repair method, the damaged cell is identified and removed from the battery pack, and a new cell is installed in its place. This helps restore the battery’s overall performance. 2. Module replacement: In some cases, rather than replacing individual cells, an entire module of cells may need to be replaced. Both of these methods require the faulty cells or packs to be identified, first by scanning and reading the data on voltage, SOC and SOH of the cells (or modules). Once replacements have been determined, the new ones must be balanced to match the existing cells. This requires specialist equipment. In some cases, the battery’s performance is improved by recalibrating or restoring its cells. This procedure involves charging and discharging the battery under controlled conditions to balance the cell voltages and reduce any memory effect or capacity loss. Reconditioning can sometimes help rejuvenate a degraded battery and improve its overall performance. EV manufacturers often release software updates for their vehicles, including updates specifically for the battery management system (BMS). These updates can optimise the battery’s performance, improve charging efficiency and address any known issues or limitations. In cases where the battery is severely damaged or degraded, it may need to be replaced entirely. Figure 9.55 shows a high-voltage EV/HEV battery service tool, the Midtronics GRX-5100 performs full-battery pack service for hybrid and electric vehicles: X safely discharges energy from the battery pack X individually balances battery pack modules to ensure optimal pack operation X continuously monitors voltage and temperature during service X on-screen verification that the battery is properly connected and operations can safely begin

Figure 9.55  EV/HEV battery service tool (Source: www.midtronics.com) X captures vehicle VIN and generates a detailed battery pack status report This equipment is used without removing the pack. A similar kit is available for balancing individual cells or modules after removal from the battery pack.

9.6.2  Balancing Battery cell balancing refers to the process of equalising the state of charge (SOC) or voltage levels of individual cells within a battery pack. In a battery pack, there are multiple cells connected in series or parallel to achieve the desired voltage and capacity. Over time, due to variations in cell characteristics and usage patterns, the cells may experience imbalances in their SOC or voltage levels. Cell balancing is essential to ensure optimal performance, longevity and safety of the battery pack. Imbalances can lead to several issues, such as reduced overall capacity, decreased energy efficiency, accelerated aging of cells and potential safety hazards. The cell-balancing process involves redistributing energy or charge between cells to bring them to a similar SOC or voltage level. This can be done through various techniques depending on the battery chemistry and the balancing system used. Common methods include 1. Passive balancing dissipates energy as heat from cells with higher SOC or voltage levels. This is achieved through passive resistors connected in parallel with each cell.

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9 Diagnostics 2. Active balancing involves transferring energy between cells by using additional circuitry, such as switching devices or integrated circuits. Energy is transferred from cells with higher SOC or voltage to those with lower levels. 3. Top balancing involves equalising the higher voltage cells in a battery pack, while bottom balancing focuses on equalising the lower voltage cells. These methods are used in certain battery chemistries to optimise the cell-balancing process. The balancing process is typically controlled by a battery management system (BMS) that monitors and manages the individual cells’ SOC, voltage and temperature. The BMS ensures that the cells operate within safe limits and initiates the cell-balancing process, when necessary, either during charging or discharging. By maintaining cell balance, battery cell balancing helps maximise the overall capacity, extend the battery pack’s lifespan, improve energy efficiency and enhance the safety

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and performance of the battery system as a whole.

9.7 Summary All the waveforms shown previously are from a correctly operating car so are ‘known good’. This is a great way to learn more about how systems work, and, of course, they are a useful comparison that you can use when testing a vehicle with a fault. A key takeaway note is just how much testing can be done without disconnecting or dismantling components on the vehicle. EVs are the future, like it or not, so this sort of work will become more common. It is hard to find the time in a busy workshop, but it is a fascinating area of technology – so plug in your scopes and start measuring!

Note 1 The electricity at work regulations 1989, Regulation 16, p. 42.

CHAPTER

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High-voltage pathway for the independent workshop 10.1 Introduction The automotive industry is witnessing a paradigm shift, transitioning from the oncedominant internal combustion engine (ICE) vehicles to the technologically advanced realm of electric vehicles (EVs) and hybrids. These cutting-edge innovations, coupled with increasing environmental awareness and supportive government policies, have fuelled an explosive growth in the EV and hybrid markets globally. As we step into a new era of sustainable mobility, the role and responsibilities of traditional garage owners are evolving rapidly, necessitating an agile response to stay relevant and profitable. For many, the mention of EVs and hybrids might evoke images of high-tech gadgets, complex electrical systems, and softwaredriven functionalities. While it’s true that these vehicles are significantly more technologically advanced than their ICE counterparts, at their core, they are still vehicles. They still need to stop, steer and stick to the road – the foundational elements of any vehicle, regardless of the technology under the bonnet.

Figure 10.1  Don’t be daunted by change – there is help out there! In other words, the principles of vehicle maintenance that garage owners have honed over years of working with ICE vehicles still apply. The brakes that allow vehicles to stop safely, the steering systems that ensure precise control and the tyres and suspension that keep the vehicle firmly planted to the road – all these systems remain crucial in EVs and hybrids. Moreover, due to the increased weight and different torque delivery of EVs and hybrids, services such as wheel alignment DOI: 10.1201/9781003431732-10

10  High-voltage pathway for the independent workshop and tyre replacement become even more important. However, there’s no denying that EVs and hybrids bring with them a unique set of maintenance needs. Components like batteries, motor controllers, charging systems and regenerative braking systems necessitate a new set of skills and tools. Additionally, the increased reliance on software for controlling various vehicle functions means that issues might not always be mechanical in nature but could also be related to the software. As such, the traditional spanner and screwdriver need to be supplemented with diagnostic tools and software knowledge. This transition might seem daunting, but it is also a source of immense opportunity. The EV and hybrid market is expanding at an unprecedented rate and shows no signs of slowing down. As per recent studies, EV sales are projected to reach 26 million units annually by 2030, accounting for more than a quarter of the world’s car fleet. Therefore, garage owners who adapt their businesses to cater to this emerging market stand to gain a significant competitive advantage. In this chapter, we aim to guide independent garage owners through this transitional journey. From understanding the EV/hybrid market and adapting business models, to setting up the workspace for EV/hybrid maintenance and building relationships with manufacturers and suppliers, we’ll delve into the key steps required to succeed in this new automotive landscape. Let’s embark on this exciting journey together, evolving with the industry to ensure that the vehicles of the future continue to stop, steer and stick to the road.

10.2 Analysing the EV/hybrid market Understanding the market you’re serving is the foundation of any business strategy, and transitioning to the maintenance of EVs and

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Figure 10.2  An independent workshop can see a wide variety of vehicles with new technologies sitting alongside much older vehicles hybrids is no exception. This section explores the demographics of EV and hybrid owners, common issues that require garage services and the projected growth of the EV/hybrid market.

10.2.1  Demographics of EV/ hybrid owners The profile of EV and hybrid owners has evolved significantly over the last decade. Early adopters were generally environmentally conscious individuals, driven by the aspiration to reduce their carbon footprint. They were typically well-off, able to afford the higher upfront costs of these vehicles. Today, the demographics have expanded dramatically. The declining costs of EVs and hybrids, coupled with increasing awareness about climate change, have made these vehicles attractive to a broader range of consumers. Now, the typical EV/hybrid owner could be anyone from a college student wanting a low running cost vehicle, a middleaged professional concerned about the environment, or a retiree attracted by the lower maintenance needs of these vehicles. Moreover, as the EV charging infrastructure improves, these vehicles are becoming

10  High-voltage pathway for the independent workshop

Figure 10.3  More local governments operate within ultra-low emissions zones and require vehicles to suit increasingly appealing to people living in apartments and urban areas who previously may not have considered an EV due to charging constraints. Businesses and government agencies are also jumping on the bandwagon, replacing their fleets with EVs and hybrids to meet sustainability goals and lower operational costs.

10.2.2  Common issues that require garage services While EVs and hybrids are often lauded for their lower maintenance requirements compared to ICE vehicles, they are not without their unique set of issues and are highly likely to be far more maintenance centric than their ICE forebearers. Understanding these common problems

will help garage owners prepare to offer the right services. Brake fluid changes are more complex for an EV, and quite often specialist equipment to change it is required. One of the main issues is related to their increased weight and different torque delivery. This puts more strain on the tyres, leading to faster wear and tear. Consequently, regular wheel alignment and tyre rotation and replacement become crucial services for EV and hybrid owners. Misalignment can not only cause uneven tyre wear but also impact the vehicle’s range – a key concern for EV owners. Air-conditioning servicing is another critical service. Unlike ICE vehicles, where the AC is often considered a comfort feature, in many EVs and hybrids, it plays a vital role in cooling the battery and ensuring optimal performance.

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10  High-voltage pathway for the independent workshop projections suggest that this trend is set to continue. This growth is expected to be fuelled by factors such as falling battery costs, improving charging infrastructure, increasing environmental awareness and supportive government policies. What does this mean for garage owners? Simply put, the demand for EV and hybrid maintenance and repair services will continue to grow exponentially. Traditional garage owners who can adapt their businesses to cater to this market stand to benefit immensely from this trend. Those who can establish themselves as reliable service providers for EVs and hybrids early on will have a significant competitive advantage as the market expands.

10.3 Adapting your business model

Figure 10.4  Brake fluid change machine Regular servicing is crucial to maintain this system’s efficiency and longevity. Remember There isn’t a belt to drive an air-conditioning compressor for an EV, so these units are often high-voltage and require suitably qualified technicians to work with them. Moreover, battery health is a major concern for EV and hybrid owners. Over time, the battery’s capacity can degrade, affecting the vehicle’s range. Garage services will need to offer battery health checks and cell balancing. In some cases, battery replacements could be required.

10.2.3  Projected growth of the EV/hybrid market The EV and hybrid market has been on a steady growth trajectory, and current

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With a clear understanding of the EV and hybrid market landscape, the next logical step is to adapt your business model to this new reality. This involves adjusting service prices, offering EV-specific services and fostering relationships with EV and hybrid owners.

10.3.1  Adjusting service prices In the initial stages of transition, you may find that servicing EVs and hybrids could require more time and specialist knowledge compared to ICE vehicles. This is mainly due to the complexity of their systems, the need for special tools and diagnostic equipment and the safety considerations when working with highvoltage components. In addition, it’s important to recognise that the maintenance cycle for EVs and hybrids is different. For example, they typically require fewer lubricant and other fluid changes (or close to very few in the case of pure EVs) but might need more frequent wheel alignments and tyre rotations and replacements due to their weight and torque characteristics.

10  High-voltage pathway for the independent workshop experience when explaining about component failure or basic maintenance requirements if this belief is in place. Wheel alignment and tyre services are key. With their heavier weight and different torque delivery, EVs and hybrids tend to wear out their tyres faster than ICE vehicles. Regular wheel alignment checks and adjustments can help ensure optimal tyre life, improve vehicle handling and even enhance range by reducing rolling resistance. Air-conditioning services also become critical in the context of EVs and hybrids. In many of these vehicles, the AC system plays a dual role – providing comfort for the occupants and, at times, providing the optimum temperature for the batteries. Regular servicing can help ensure the system’s efficiency, thereby preserving the battery’s health and performance. Figure 10.5  A drain plug from a failed singlespeed box on a BMW i3, mileage 30,000 miles

Consequently, you’ll need to adjust your service prices to reflect these realities. You may need to charge more for certain services that require specialist knowledge or tools, while other services may be cheaper due to less frequent need. Additionally, bundling certain services, like wheel alignment and tyre checks, could be a great way to provide value to your customers while ensuring regular business.

Battery health checks are another important service. Over time, the capacity of an EV’s or hybrid’s battery can degrade, affecting the vehicle’s range. Offering regular battery health checks can help owners understand their battery’s state of health and plan for potential replacement if necessary. Lastly, due to the digital nature of these vehicles, services related to software updates, diagnosing and fixing software glitches and resetting digital service records will be essential. Offering these services can set your garage apart as a one-stop-shop for all EV and hybrid maintenance needs.

10.3.2  Offering EV-specific services

10.3.3  Building relationships with EV/hybrid owners

As mentioned earlier, EVs and hybrids come with their own set of maintenance needs. It’s crucial to develop a comprehensive understanding of these requirements and offer EV-specific services. Quite often there is a misconception from motorists that these vehicles need little or even no maintenance and repair! This might be a different

Establishing strong relationships with your new customer base is key to ensuring repeat business and referrals. In today’s digital age, customer expectations have evolved; they expect transparency, clear communication and a hassle-free service experience. To meet these expectations, it’s crucial to invest in training your team in customer service

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10  High-voltage pathway for the independent workshop whether it’s through responsible waste disposal, using renewable energy or even just reducing paper usage, you can build a deeper connection with this customer base.

10.4 Setting up the workspace for EV/hybrid maintenance

Figure 10.6  Joining networks can help promote your business skills. This includes being able to explain complex technical issues in a language that customers understand, keeping them informed about the progress of their vehicle’s service and being honest and upfront about costs.

Successfully transitioning to EV and hybrid maintenance is not just about updating your business model and services, but it also involves modifying your workspace to accommodate the specific needs of these vehicles. This includes understanding high-voltage safety considerations, placing EV-specific equipment optimally and ensuring adequate ventilation for battery work.

10.4.1  High-voltage safety considerations

Leveraging technology can also help improve the customer experience. For example, using a digital platform to manage bookings, provide service updates and maintain digital service records can greatly enhance convenience for your customers.

Working with EVs and hybrids involves dealing with high-voltage systems that, if not handled correctly, can pose serious safety risks. Therefore, it’s vital to implement stringent safety procedures and equip your garage with the necessary safety equipment.

Moreover, remember that many EV and hybrid owners are passionate about sustainability. By showcasing your commitment to eco-friendly practices,

All staff should be trained in high-voltage safety procedures, including proper disconnection and reconnection of the high-voltage system before and after service. Emergency procedures should be in place and communicated clearly to all staff members. It’s also crucial to ensure that high-voltage components are clearly marked to avoid accidental contact. Invest in high-voltage personal protective equipment (PPE) such as insulated gloves, safety boots and face shields. Remember that regular rubber gloves or work boots don’t offer adequate protection against high-voltage electrical shock.

Figure 10.7  Digital tools are just as important as mechanical tools in the modern workshop

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Moreover, consider acquiring insulated tools that are specifically designed for high-voltage work. These tools are built to withstand highvoltage without conducting electricity, thus protecting the user from electrical shock.

10  High-voltage pathway for the independent workshop 10.4.2  EV-specific equipment placement Incorporating EV-specific equipment into your workspace requires thoughtful planning to ensure efficient workflow and safety. This equipment can range from specialised diagnostic tools to battery lifters and charging stations. These are covered earlier in the book. Try to position these tools and equipment in locations that optimise their usage. For instance, battery lifting equipment should be located near where it will be used. The charging station, on the other hand, should be conveniently accessible for charging vehicles or during specialist diagnostic work. Safety First There are very few circumstances when a vehicle needs to be charging and work carried out. You must be qualified to do this. Ensure that high-voltage equipment is stored and used in areas where there is minimal risk of contact with water to avoid the risk of electrical shock. Similarly, keep flammable materials away from battery charging and testing areas.

Figure 10.8  Whilst reconfiguring the workshop, dollies can serve as a short-term solution, remember to check for correct lifting points!

In terms of workspace layout, strive for a configuration that allows for efficient movement between different tasks, minimises congestion and promotes safety. Remember that some EV-specific tasks may take different timescales to their ICE counterparts, so plan for a workflow that allows other tasks to proceed simultaneously.

10.4.3  Adequate ventilation for battery work When working with EV batteries, adequate ventilation is paramount. This is because when a battery is damaged, it can emit gases that can be harmful if inhaled or even cause an explosion in confined spaces. As the car is potentially booked in for repair or the history may be unknown, all reasonable care must be taken. Ensure your workspace has a well-designed ventilation system that can effectively remove these gases and provide fresh air. This is particularly important if you’re working in a closed environment or if your workspace is small. Depending on the specifics of your garage, solutions could range from natural ventilation, mechanical extraction systems or a combination of both. This is an area that may also be impacted by legislation, so it is well worth keeping up to date through the government website about ventilation.

Figure 10.9  Battery pack work carried out in a well-ventilated workshop

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10  High-voltage pathway for the independent workshop During the installation of the ventilation system, consider factors such as the volume of air that needs to be replaced per hour, the size and location of inlet and outlet vents and the direction of airflow. The system should be regularly maintained to ensure it remains effective. Remember, while it’s crucial to ensure adequate ventilation, it’s equally important to equip your staff with appropriate personal protective equipment (PPE), such as masks and gloves, when working with batteries. They should also be trained on the risks associated with battery gases and the importance of maintaining the ventilation system. By taking the time to plan your workspace for EV and hybrid maintenance, you’ll not only enhance safety but also improve productivity and efficiency, all of which contribute to the success of your transition.

10.5 Building relationships with suppliers, industry associations and technology providers As a small independent garage transitioning to EV and hybrid maintenance, forming strategic relationships is crucial to your success. These

relationships should be not only with parts suppliers but also with industry associations, providers of technical information and garage management system providers. In this section, we’ll explore the benefits of these relationships and provide guidance on how to establish them.

10.5.1  Benefits of relationships Parts suppliers: Establishing strong relationships with reliable parts suppliers can grant your garage access to competitive pricing and availability. This can significantly reduce your operation costs and ensure timely services, thus improving customer satisfaction. Industry associations: Associations like the Institute of the Motor Industry (IMI) play a pivotal role in shaping industry standards and legislation. Being associated with them can provide your garage with valuable insights into industry trends, upcoming legislative changes and qualification and apprenticeship resources. This information can help you stay ahead and ensure your services align with industry best practices. Technical information providers: Technical information is key to diagnosing and fixing issues in EVs and hybrids. Establishing relationships with providers of technical information can provide your garage with access to up-to-date, comprehensive information that can improve service quality. Authorised examiner consultants: AECs are very useful for workshops that also offer MOT testing, especially with the emergence of EVs that are smaller than conventional vehicles and may require an examination of classification at first presentation.

Figure 10.10  Sharing experiences at networking events can expand your knowledge quickly

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Garage management systems: Modern garage management systems are becoming increasingly community-led, fostering a “hive mind” environment where garages can assist each other. Being a part of such a community can provide your garage with valuable insights, advice and assistance.

10  High-voltage pathway for the independent workshop reliable associations like IMI, comprehensive technical information providers and community-led garage management systems.

Figure 10.11  An AEC can be a valuable contributor when understanding EV MOT classifications

10.5.2  How to establish these relationships Identify potential partners: Start by identifying potential partners who align with your business’s needs. Look for reputable parts suppliers who offer competitive prices,

X Reach out: Once you’ve identified potential partners, reach out to them. Express your interest in forming a relationship and discuss how this could be mutually beneficial. X Negotiate terms: After initial contact, negotiate the terms of the relationship. This could include pricing, access to information, technical support, for example. Ensure the terms align with your business goals. X Formalise relationship: Once the terms are agreed upon, formalise the relationship. This could be in the form of a contract or a mutual agreement. X Maintain the relationship: Finally, maintaining the relationship is key. Regular communication, feedback and collaboration can ensure a beneficial long-term relationship. By forming strategic relationships with suppliers, industry associations and technology

Figure 10.12  Showcase these relationships within signage and on your website

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10  High-voltage pathway for the independent workshop providers, your garage can gain valuable resources, insights and support that can significantly aid your transition to EV and hybrid maintenance.

10.6 Opportunities and challenges The shift from traditional internal combustion engine (ICE) vehicles to EVs and hybrids brings both opportunities and challenges for independent garage owners. Recognising these will help you strategically position your business for the transition and mitigate potential obstacles.

10.6.1  The growing market for EV repair and maintenance Transitioning early to servicing EVs and hybrids presents a range of significant opportunities for your garage. Firstly, the market for EV and hybrid repair and maintenance is rapidly growing. With increasing awareness about environmental sustainability, more consumers are turning to EVs and hybrids. Governments around the world are also pushing this transition, with many setting ambitious targets for phasing out ICE vehicles. This trend is likely to continue,

Figure 10.13  Electric vehicles can come in all shapes and sizes

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creating a burgeoning customer base for EV and hybrid services. Secondly, early adoption of EV and hybrid servicing can give your garage a competitive edge. By being one of the first in your area to offer these services, you can position your garage as a pioneer and a go-to expert for EV and hybrid repairs and maintenance. This can significantly enhance your garage’s reputation and customer trust. Furthermore, transitioning early allows you to build competence over time. EVs and hybrids come with new technologies that require time to understand and master. By starting early, you can learn at a comfortable pace and make mistakes when the stakes are lower. Finally, offering EV and hybrid services can diversify your revenue streams. These services can be priced premium due to their specialised nature, enhancing your garage’s profitability. Although this situation is fast changing, it would be sensible to watch these trends closely.

10.6.2  Potential challenges and how to overcome them While the opportunities are substantial, the transition to servicing EVs and hybrids also comes with potential challenges. One of the main concerns is the investment required. Purchasing EV-specific equipment and tools, upgrading your workspace and training your staff can be costly. To mitigate this, consider gradually phasing in these changes to spread out the costs. You could also explore partnerships and affiliations that could offer financial benefits or assistance. Make sure your accounts accurately reflect your investment to maintain tax affairs in order. Another challenge is the technical complexity of EVs and hybrids. Their advanced electronic systems and high-voltage components can be daunting. However, with comprehensive training and continuous professional development, your staff can become proficient

10  High-voltage pathway for the independent workshop over time. Relationships with technical information providers can also be invaluable in this regard. Lastly, there is the challenge of staying up-todate with the rapidly evolving EV technology. To overcome this, ensure regular training for your staff and keep an eye on industry trends and advancements. Membership in industry associations can also provide access to a wealth of up-to-date information as well as a convenient method of maintaining and recording your CPD. The transition to EV and hybrid servicing is a significant step, filled with both opportunities and challenges. By recognising these early and proactively addressing them, your garage can smoothly navigate this transition and emerge as a trusted service provider for EVs and hybrids.

10.7 Suggested checklist for transitioning to EV/hybrid maintenance Transitioning your garage to service EVs and hybrids requires careful planning and execution. This comprehensive checklist outlines the key steps in this process, guiding you from understanding the market to preparing for future growth. Understanding the market: X Research EV/hybrid market: Study your local and global market for EVs and hybrids. Understand the demographics, buying behaviours and preferences of EV/hybrid owners. X Identify common issues: Familiarise yourself with the common issues that EVs and hybrids encounter. This includes

Figure 10.14  Training event at Delphi in Warwick

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10  High-voltage pathway for the independent workshop understanding the importance of wheel alignment, air conditioning and tyre wear, among others. X Forecast market growth: Research projected growth of the EV/hybrid market. Understand potential customer volume and plan your business capacity accordingly. Adapting your business model: X Revise service prices: Consider adjusting your service fees to reflect the specialised nature of EV and hybrid services. Ensure your pricing is competitive but profitable. X Offer EV-specific services: Identify and offer services specific to EVs and hybrids, such as battery maintenance and electronic system diagnostics.

X Improve customer relations: Develop strategies to build strong relationships with your new customer base. This includes excellent communication, transparency and quality service. Setting up your workspace: X Prioritise safety: Understand and implement high-voltage safety measures. This includes acquiring safety equipment and training your staff on safe handling of EVs and hybrids. X Arrange workspace: Plan for the integration of EV-specific equipment into your existing workspace. Consider the space and power requirements of these tools. X Ensure adequate ventilation: If you plan on servicing batteries, ensure your garage has adequate ventilation to avoid hazardous fumes.

Figure 10.15  Garage Hive offer a garage management solution but also have a resource for forecasting

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10  High-voltage pathway for the independent workshop Building relationships: X Find reliable suppliers: Establish relationships with reliable parts suppliers for competitive prices and availability. X Join industry associations: Consider joining industry associations like the IMI for insights into legislation, current industry news and qualification and apprenticeship resources. X Partner with information providers: Form relationships with providers of technical information for access to comprehensive, up-to-date information. X Choose a management system: Select a community-led garage management system for community support and collaboration. X Consider attending trade shows: Along with training, trade shows can be a valuable (and

enjoyable) time to network and talk to other technicians. Addressing opportunities and challenges: X Recognise opportunities: Understand the opportunities in the EV/hybrid market and strategise to leverage them. X Overcome challenges: Identify potential challenges in your transition and develop strategies to overcome them. This includes financial planning, training and staying updated on EV technology. Preparing for future growth: X Plan for expansion: As the EV/hybrid market grows, plan for potential expansion of your business. This could include increasing staff, workspace or service offerings. X Invest in continuous learning: Encourage continuous professional development

Figure 10.16  You bump into all sorts of people on the stands at trade shows!

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10  High-voltage pathway for the independent workshop for your staff to keep up with the rapidly evolving EV technology. By following a checklist such as this, your garage can smoothly transition to servicing EVs and hybrids, setting itself up for success in the burgeoning EV market.

10.8 Summary As we reach the conclusion of this chapter, it’s vital to reiterate the importance of transitioning your garage services to cater to electric vehicles (EVs) and hybrid electric vehicles (HEVs). As the shift towards sustainable mobility gains momentum worldwide, it’s evident that the automotive industry is on the brink of a substantial transformation. This new reality presents an unmissable opportunity for garage owners to adapt and partake in an exhilarating new chapter of automotive history. Bear in mind the quintessential principle of vehicle maintenance – that every vehicle, irrespective of its power source, needs to ‘stop, steer and stick to the road’. Whether it’s an EV, an HEV or a traditional ICE vehicle, this tenet holds true. As a garage owner, your proficiency in maintaining these critical systems is a valuable asset that will continue to serve you in this new era of EVs and hybrids.

Figure 10.17  An older hybrid car presented for MOT testing

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Indeed, servicing EVs and HEVs involves new challenges like understanding high-voltage systems, electric drive units and advanced battery technologies. However, instead of viewing these as daunting hurdles, see them as opportunities for expanding your expertise and enhancing your service offerings. Air-conditioning systems, which played a comparatively minor role in ICE vehicles, will take centre stage in EVs and HEVs, given they can have a role in battery thermal management but are often more used to regulate the temperature of the cabin. Regular wheel alignment, critical for energy efficiency, will also gain importance due to the heavier weight of EVs and hybrids. Tyre maintenance and replacement will require renewed attention, considering EVs and hybrids deliver torque differently and carry heavier weight than ICE vehicles. As the world moves towards digital solutions, handling digital service records smoothly will be another essential aspect of modern garage operations. Similarly, as customer expectations evolve, garage owners must hone their communication skills to match the demands of a well-informed and discerning clientele. In essence, as the adage goes, ‘the business of business has never been so business-like’.

Figure 10.18  Mercedes EV with separate water-cooled systems for the AC system and HV battery pack

10  High-voltage pathway for the independent workshop This is particularly relevant in the current automotive landscape. The evolution isn’t just technological; it encompasses every aspect of your garage operations. As you learn to work on advanced EVs and hybrids, your business practices need to keep pace, ensuring they fulfil modern motorists’ expectations. The switch to EV and hybrid servicing might seem overwhelming, but the early adopters who manage this transition well can position themselves as pioneers in this growing field, earning customer trust and establishing a robust reputation. Remember, transitioning to EV and hybrid servicing is more a marathon than a sprint. It requires careful planning, investment, continuous learning and, most importantly, adaptation. However, with the right approach and resources, this transition can turn into an exciting evolution, steering your business towards a sustainable and prosperous future. With the insights shared in this chapter, you are now equipped to embark on this remarkable journey into the world of electric and hybrid vehicles. Embrace the opportunities, adapt your business practices and steer your garage into a promising future, keeping pace with both technology and customer expectations. Your business has never been so business-like, and the road ahead has never been so electrifying.

10.9  Case studies In this section, we will delve into two reallife case studies of UK garages that have successfully made the transition to servicing EVs and hybrids, offering insights and key lessons.

10.9.1  Lindleys autocentres (Nottingham) Lindleys Autocentres, a distinguished name in the UK automotive service industry, is an example of an enterprise that recognised

and acted on the rising trend of data-driven decisions. What began as a modest garage in Arnold eventually expanded into a successful chain of branches scattered across Nottingham, thanks to its strategic use of Garage Hive. Garage Hive, a community-driven garage management system powered by Microsoft Business Intelligence, provided Lindleys Autocentres with an efficient way to manage its operations, from customer bookings to billing. The platform, continuously enhanced by contributions from its user community, including Lindleys, helped Lindleys streamline its operations and leverage data analytics for business insights. Simultaneously, Lindleys invested in staff training, obtaining the necessary certifications to handle high-voltage systems safely, thereby readying its team for the influx of EV and hybrid vehicles. It also ensured the acquisition of specialised tools and equipment required for EV and hybrid repairs and services. Lindleys upheld its guiding principle of ‘stop, steer and stick to the road’, applying it to its approach to EVs and hybrids as well. Lindleys Autocentres’ successful transition underscores the importance of embracing modern business tools while upskilling and adapting to new technologies in the automotive industry.

10.9.2  Cleevely EV (Cheltenham) Cleevely EV in Cheltenham stands as a testimony to successful adaptation and foresight. A part of the family-owned Cleevely Motors, the garage underwent a transformation to become one of the first independent businesses in the UK to specialise in EVs and hybrids. It was the third generation, Matt Cleevely, who saw the potential of the EV market and took the plunge. Under Matt’s leadership, Cleevely EV became an IMI-certified EV service centre, with

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Figure 10.19  Lindleys has won a number of prestigious awards and expertise required to service and repair EVs and hybrids. Cleevely EV also reached out to the community for knowledge sharing and technical support. It fostered relationships with parts suppliers and technical information providers to ensure its services remained current and comprehensive. The Cleevely EV story teaches us that seizing opportunities, making strategic investments in skills and nurturing relationships can propel a garage to a leadership position in the EV service industry. Figure 10.20  Proprietor Matt Cleevely (right) directing a diagnostic approach Matt himself becoming an IMI-certified EV technician. This investment in training and certification endowed the team with the skills

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These case studies present valuable lessons for any garage planning to venture into the EV and hybrid sector. They demonstrate that the road to transition, while challenging, can lead to success through strategic planning, training, adaptation and efficient business management.

Index AC charging 97, 167, 168, 170, 172 AC electric shock 21 AC motors 137, 140 alkaline batteries 113 alternating current see AC 22, 83, 148, 167, 172, 177, 179 Ampere’s law 55 anodes 116 anodes and cathodes 116 arch flash 24, 31 asynchronous motor 137, 138, 147 axle-split parallel hybrid 69, 71 battery 1, 2, 3, 26, 27, 28, 32, 39, 41, 46, 105, 109, 149, 202, 223, 225, 240 battery charger 156 battery control system 156, 157 battery life and recycling 108 battery repair 223 battery replacement 26, 168, 170, 230 battery transport and packaging regulations 95 – 96, 108, 198 brakes 5, 9, 18, 65, 67, 83, 88, 89, 222, 223 brushless DC motors (BLDC), 140 burns 11, 18, 21, 24, 31, 32, 190, 195 CAN 41, 88, 95, 134, 221 capacitors 1, 22, 29, 48, 56, 57, 58, 100, 122, 123, 151, 159, 178 – 180, 186, 209 carbon dioxide 6, 10 carbon resistors 51, 56 CAT ratings 36 cathodes 116 cell balancing 157 – 158 ceramic substrate 59 charging cables 86, 165, 173, 177, 180, 188

circuit and electronic symbols 57 circuit breaker 22, 25 – 26, 86 circuit symbols 48 – 49, 57 Combined Charging System (CCS) 170, 172 Control of Substances Hazardous to Health (COSHH), 26 cooling 64, 75 – 77, 82, 85 – 88, 91 – 92, 124 – 126, 134 143 – 144, 146, 148, 160 – 161, 176 – 177, 190, 229 copper losses 144 crash safety 17, 95 data link connector 41, 202 DC charging 97, 168, 170, 176 DC electric shock 24 DC motors: brushless (BLDC) 90, 140, 143 DC to DC converter 82, 90, 159 de-energizing 16 – 17, 29, 93, 95, 179, 187, 190 – 192, 196, 200, 208, 212 definitions and laws 54 diagnostics 4, 33, 40, 41, 42, 151, 201 – 226, 228, 230, 233, 238, 242 digital multimeter, 33 – 34 diodes 50, 56 – 58, 90, 209, 221 direct current (DC) 19, 24, 83, 90, 158, 167168, 172, 177, 179 domestic charge points 164 driver interface 83 driving cycle 8, 99 efficiency 5, 58 – 59, 64, 67, 71, 74, 77, 79 – 80, 83 – 85, 87, 90, 92 – 93, 97, 99, 106, 110 – 111, 121, 123, 126, 131, 137, 143 – 144, 146 – 147, 149, 153 – 154, 156, 158, 165, 178, 180 – 182, 220, 225 – 226, 230 – 231, 234, 240

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Index electric motor principles 53 electric power assisted steering (ePAS) 89 electrical principles 45 electrical safety gloves 20 Electricity at Work Regulations (UK) 16, 202, 226 electromagnetic interference (EMI) 180 electromagnetic radiation (EMR) 181, 188 electromagnetism 52 electron 3, 16, 19, 28, 33, 34, 38, 41, 45 – 60, 63 – 65, 70 – 71, 73, 75, 78, 82, 83, 89, 90, 91, 96, 101, 116, 120 – 122, 125, 132, 134, 135, 137, 139, 140, 147, 148, 151, 153, 154, 155, 157, 158, 161 – 180, 186, 188, 189, 192, 193, 236, 238 electronic components 28, 46, 55, 64, 75 electronic symbols 57 electronically commutated motor (ECM) 137, 139 – 140 emergency response 194 – 195 emergency start 193 energy densities 123, 134 external rotor 100 Faraday’s law 54 fast charging 6, 125, 158, 163, 168, 172, 174, 175, 177 fibrillation 23 – 24 field effect transistor (FET) 58 – 59 fire 4, 12, 18, 24, 26, 27, 31, 32, 83, 97, 126 – 127, 133 – 134, 195 – 196, 199 – 201 Fleming’s rules 55 flywheel 39, 63, 70, 123 footwear protective 19 fuel cells 120 – 121 fuses 25, 28, 86 generator, 2, 3, 46, 47, 50, 52, 53, 55, 57, 65, 68, 69, 70, 71, 73, 74, 9, 80, 83, 87, 96, 97, 103, 142, 143, 149, 152, 153, 154, 180, 189, 194, 215, 216, 221, 222 ghost voltage 38 gloves electrical safety 17, 18, 19, 20, 40, 190, 222, 232 Hall Effect 37, 140, 141 harmful event flowchart 128

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hazard management 15 – 43, 190 heat pumps 88, 92 heating and cooling systems 91 heating effect of current flow 47, 50, 124 heavy vehicles 96, 98 – 100 high and low voltages (AC and DC) 19 high energy cables and components 20 high voltage cables 18, 21, 27, 81, 188, 189, 191 high voltage DC (HVDC) relays 149, 152 high voltage systems/components 15, 16, 18, 19, 27, 31, 32, 37, 38, 40, 93, 94, 95, 96, 150, 187, 191, 192, 194, 196, 201, 202, 206, 208, 212, 215, 216, 232, 240, 241 high voltage tools 40 HVAC 92 – 93 Hybrid and Electric Vehicle Repair Alliance (HEVRA) 31, 77, 225 hybrid electric vehicles (HEVs) 2, 68, 133, 240 IMI TechSafe 12, 16 – 17, 201 – 202 In Cable Control Box (ICCB) 170 inductance 49, 56, 59 inductive charging 168 – 169, 180, 181 insulated gate bipolar transistor (IGBT) 58, 85, 96, 153 insulated tools 1718, 28 – 29, 40, 232 insulation 4, 17, 25, 28, 29, 31, 38, 39, 40, 81, 82, 96, 144, 145, 152, 188, 203, 204, 205 – 210, 214, 215 insulation resistance 17, 29, 39, 96, 205, 206, 208, 209, 215 insulation testing 203 integrated circuits, 59 – 60, 157, 226 integrated motor assist (IMA) 63, 66, 142 inverters 6, 53, 59, 83, 85, 97, 99 – 100 iron losses 144 kilowatt hour (kWh) 83, 105 – 106 kinetic energy recovery system (KERS) 67 Kirchhoff’s law 54 lead acid batteries 111 leakage of hazardous substances 197 Lenz’s law 54 let go current 24 life cycle assessment 9 – 10

Index liquid cooling 87 – 88, 92, 124 – 125, 146 lithium-ion battery 12, 73 – 74, 77, 87, 92, 117 – 118, 124, 126, 130, 135, 157, 175, 195, 198 lithium-sulphur battery 116 live data 41, 201 – 204, 216 magnetism 24, 52 – 53, 138, 197 mechanical losses 144 medical devices 16, 26, 202 Megger 38, 203, 205 metal oxide semiconductor field effect transistor (MOSFET) 59 microprocessor control unit (MCU) 148, 153 motor control 14, 68, 83, 91, 148, 149, 152, 153, 161, 228 motor efficiency 143 – 144 multimeters 33 – 38, 187, 208, 210, 211 – 215, 217 multiphase inverters/motors 98 mutual induction 53, 168 negative temperature coefficient (NTC) 56, 156 nickel-cadmium battery 111 – 112, 123 nickel-metal hybrid battery 64, 108, 111, 113 – 114, 123, 149 Ohm’s Law 37, 49, 54 onboard diagnostics (OBD) 40 – 41 oscilloscopes 33 – 35, 57, 215 – 216, 218 pacemakers 26, 201 parallel circuit 51 parallel hybrid 69 – 72, 77 pedestrian safety 18 personal protective equipment (PPE) 4, 18 – 19, 28, 232, 234 PicoScope 34 – 35, 154, 214 – 216, 219, 220, 222 – 223 plugin hybrid electric vehicles (PHEVs) 2, 6, 83, 149, 217 power assisted steering 83, 89 power grid capacity 13, 53, 177 power losses 59 power split hybrids 69, 71 – 73 public charging points 12

pulse width modulation (PWM) 58, 154, 173, 221 pure electric vehicle (PEV) 1, 6, 78, 97, 108 quantities symbols and units 48 range anxiety 5, 71, 178 recycling 9, 10, 108, 109, 134, 199, 200 re-energizing 17, 29, 190 – 192 remote operation keys 26 – 27 residual current breaker with overcurrent (RCBOs) 25 residual current device (RCD) 25, 170 resistance 7, 17, 24, 29, 35 – 39, 47 – 51, 54, 56, 81, 88, 92, 96 – 97, 110, 115, 120, 123 – 124, 139, 144, 152, 173 – 174, 203 – 209, 211 – 212, 215, 217, 231 resistors 51, 56, 59, 151, 209, 225 risk and risk reduction 18 roadside assistance 193, 194 rotor position sensor 140 safe work process 26 semiconductors 50 sensors 10, 34, 35, 37, 41, 70, 71, 74, 78, 82, 89, 90, 133, 134, 140, 148, 149, 153 – 156, 164, 186, 203, 217 series circuit 51, 54 series hybrid 69, 71, 72 series parallel hybrid 69, 71 – 72 short circuit 1618, 25, 28, 29, 50, 81, 125, 152, 158, 188, 190, 196, 209 sodium-nickel chloride battery 115 sodium-sulphur battery 115, 123 solar panel 114, 164 solid state battery 133 squirrel cage rotor 137 – 138 startup and shut down 150 – 152 state of charge (SOC) 3, 10, 67 – 68, 83, 88, 109 – 113, 157 – 159, 177, 204, 225 state of health (SOH) 106, 109, 110 – 111, 231 stationary wireless power transfer (WPT) 178 – 183 stop/start system 66, 71 stray losses 144 strong hybrids 66, 70, 71 – 72 supercapacitors 172

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Index switched reluctance motor (SRM) 141 – 143 synchronous motor 63, 83, 137 – 139, 140,  147 tank-to-wheel emissions 6 – 7 technical information 185, 234 – 235, 237, 239, 242 test equipment 28, 33, 34, 39, 193, 209,  220 thermal runaway 32, 127, 134 thermistor 57, 156 torque and speed 83, 153 towing 27, 194 transistors 50, 58, 60, 85, 96, 100, 148, 151 – 152 transport and packaging regulations 95 – 96, 108, 198 tyre noise 18 ultra-capacitors 122 UNECE 7, 85, 199, 209

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valeting 4, 26 – 27 vehicle-to-grid (VG) 175 voltage 3, 4, 12, 64, 73, 75, 115, 151, 173, 197, 201, 240, 241 warning signs 4, 21, 28 – 29, 187, 192, 200, 212 warning stickers 21, 81 warranty 12, 173, 175, 192 Waste Batteries and Accumulators Regulations 108 well-to-wheel emissions 6 wheel motors 16, 63 – 64 winding shapes 144 windings 18, 53, 64, 138, 140, 143146, 148, 151,155, 182, 205 wireless power transfer (WPT) 178, 182 work categories 26 worldwide harmonized light vehicles test procedure (WLTP) 1, 5, 7, 8, 11 Zener diode 56